Toyota - Tacoma - Workshop Manual - 2006 - 2006

Page 879 Vapor Pressure Sensor: Description and Operation CIRCUIT DESCRIPTION The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTC P0450 or P0451 is recorded by the ECM when the vapor pressure sensor malfunction. Page 441 WIRING DIAGRAM Step 1 Step 2 Page 2791 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 746 CHART 12 CHART 13 Page 2644 CHART 21 Page 674 Page 1080 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 877 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2203 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3034 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2629 O2S Application Table O2S Failure Threshold Charts Page 186 EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION a. Apply battery positive voltage across terminals 86 and 85. b. Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Page 1287 TOY 730 - 73mm Toyota Oil Filter Wrench M 0219 - 74mm Oil Filter Wrench Page 8 Locations Page 519 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2758 Camshaft Position Sensor: Service and Repair COMPONENTS REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. b. Remove the bolts and camshaft position sensor. Torque: 5.4 Nm (55 kg.cm, 48 in.lb) INSTALLATION Installation is in the reverse order of removal. Page 2226 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2967 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 550 Key Reminder Switch: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1092 Step 2 Step 3 INSPECTION PROCEDURE Page 2184 Vapor Pressure Sensor: Description and Operation CIRCUIT DESCRIPTION The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTC P0450 or P0451 is recorded by the ECM when the vapor pressure sensor malfunction. Page 1293 6. INSPECT AIR CONDITIONING OPERATION Page 68 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2449 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 171 Engine Control Module: Connector Views Part 1 Of 2 Page 2845 Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Page 2100 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 407 Step 2 Step 5 Page 3075 Vapor Pressure Sensor: Testing and Inspection VSV For Vapor Pressure Sensor 1. REMOVE VSV a. Disconnect the connector and 3 EVAP hoses from the VSV. b. Remove the bolt and VSV. 2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 37 - 44 ohm at 20 °C (68 °F) If there is no continuity, replace the VSV. 3. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. 4. INSPECT VSV OPERATION Page 3323 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2905 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2729 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Diagram Information and Instructions Vapor Pressure Sensor: Diagram Information and Instructions Page 3352 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 882 Vapor Pressure Sensor: Testing and Inspection VSV For Vapor Pressure Sensor 1. REMOVE VSV a. Disconnect the connector and 3 EVAP hoses from the VSV. b. Remove the bolt and VSV. 2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 37 - 44 ohm at 20 °C (68 °F) If there is no continuity, replace the VSV. 3. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. 4. INSPECT VSV OPERATION Page 2439 Camshaft Position Sensor: Service and Repair COMPONENTS REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. b. Remove the bolts and camshaft position sensor. Torque: 5.4 Nm (55 kg.cm, 48 in.lb) INSTALLATION Installation is in the reverse order of removal. Page 741 CHART 5 CHART 6 Page 913 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Locations Testing and Inspection Headlamp Switch: Testing and Inspection INSPECT LIGHT CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY If continuity is not as specified, replace the switch. Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Page 2728 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 749 CHART 16 CHART 17 Page 2271 Page 1353 Power Steering Fluid: Fluid Type Specifications Lubricant Lubricant Type Automatic Transmission Fluid Dexron II or Dexron III Page 3143 Mass Air Flow Meter: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 380 Coolant Temperature Sensor/Switch (For Computer): Description and Operation A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the DTC P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). Specifications Thermostat: Specifications Valve Opening Temperature 80-84°C (176-183°F) Valve Lift 8 mm at 95°C (203°F) Valve Fully Closed Below 40°C (104°F) Page 2187 Vapor Pressure Sensor: Testing and Inspection VSV For Vapor Pressure Sensor 1. REMOVE VSV a. Disconnect the connector and 3 EVAP hoses from the VSV. b. Remove the bolt and VSV. 2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 37 - 44 ohm at 20 °C (68 °F) If there is no continuity, replace the VSV. 3. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. 4. INSPECT VSV OPERATION Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake 0.15-0.25 mm (0.006-0.010 in) Exhaust 0.25-0.35 mm (0.010-0.014 mm) Page 2992 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 22 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3019 Step 2 Step 3 Page 177 Engine Control Module: Testing and Inspection Related Diagnostic Procedures CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Step 1 Page 2588 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3339 Throttle Body: Service and Repair COMPONENTS REMOVAL 1. DRAIN ENGINE COOLANT 2. M/T: DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY A/T: DISCONNECT ACCELERATOR AND THROTTLE CABLES FROM THROTTLE BODY 3. REMOVE AIR CLEANER HOSE WITH RESONATOR a. Disconnect the 2 wire clamps from the air cleaner hose. b. Loosen the air cleaner hose clamps, remove the air cleaner together with the resonator. Page 2572 Step 1 Step 2 Page 411 Step 4 INSPECTION PROCEDURE Page 456 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Diagram Information and Instructions Braking Sensor/Switch: Diagram Information and Instructions Page 3047 b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Torque: 5.4 Nm (55 kgf cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 1160 Page 709 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3308 Page 923 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Page 2897 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1158 Parts Location Page 2128 Page 3036 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1111 Page 2345 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE PCV HOSES 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. DISCONNECT ENGINE WIRE a. Disconnect these connectors: - w/ A/C: A/C compressor connector - Oil pressure sensor connector - Engine coolant temperature sender gauge connector - Ignition Coil connector b. Disconnect the 4 engine wire clamps and engine wire. 5. REMOVE CYLINDER HEAD COVER Remove the 10 bolts, seal washers, cylinder head cover and gasket. 6. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley clockwise and align its groove with the "0" mark on the timing chain cover. b. Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. 7. INSPECT VALVE CLEARANCE Page 785 Oxygen Sensor: Description and Operation DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for the most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric air-fuel ratio. The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air-fuel ratio. This is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air-fuel ratio. When the air-fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN condition (small electromotive force: <0.45 V). When the air-fuel ratio is RICHER than the stoichiometric air-fuel ratio the oxygen concentration in the exhaust gas in reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive force: > 0.45 V). The ECM judges by the electromotive force from the oxygen sensor whether the air-fuel ratio is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to perform accurate air-fuel ratio control. The oxygen sensors include a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temp. of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Page 3094 How To Read Ground Points Page 2567 Page 97 Locations Page 819 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1938 Camshaft Position Sensor: Description and Operation The Camshaft position sensor (G signal) consists of a signal plate and pick up coil. The G signal plate has one tooth on its outer circumference and is mounted on the exhaust camshaft. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. Page 804 Page 421 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2861 O2S Application Table O2S Failure Threshold Charts Page 1048 Step 1 Step 2 Page 872 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 549 Page 745 CHART 11 Page 2350 - Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 9. REINSTALL CYLINDER HEAD COVER 10. RECONNECT ENGINE WIRE 11. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 12. REINSTALL PCV HOSES 13. REINSTALL INTAKE AIR CONNECTOR Page 624 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2268 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2218 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2614 Engine Bank Identification Page 743 CHART 8 CHART 9 Page 3105 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1707 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2520 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2028 Engine Bank Identification Diagnostic Trouble Code Tests and Associated Procedures Idle Air Control Valve: Diagnostic Trouble Code Tests and Associated Procedures CIRCUIT DESCRIPTION The rotary solenoid type IAC valve is located in front of the intake air chamber and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle-up and provide feedback for the target idling speed. DETECTING CONDITIONS WIRING DIAGRAM Page 2076 How To Read Ground Points Page 797 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2261 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1300 Brake Fluid: Service Precautions SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: * Eye Contact - rinse eyes thoroughly with water. * Skin Contact - wash skin with soap and water. Page 765 CHART 28 Page 2853 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 1035 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2706 Engine Control Module: Service and Repair COMPONENTS REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE LOWER FINISH NO.2 PANEL 3. REMOVE ECM a. Disconnect the 4 ECM connectors. b. Remove the 2 bolts and ECM. INSTALLATION Installation is in the reverse order of removal. Page 1145 Page 2034 A/F and 02 Sensor Identification Page 2623 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 3327 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2157 Vehicle Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 2514 Data Link Connector: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 902 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2424 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2241 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Service Precautions Service Reminder Indicators: Service Precautions SERVICE PRECAUTION All Service Reminder Indicators should be investigated or serviced immediately. Vehicle damage may result if the indicator is ignored. Page 690 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2560 Idle Air Control Valve: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2082 Oxygen Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2712 EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION a. Apply battery positive voltage across terminals 86 and 85. b. Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Page 112 Locations Page 685 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2923 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3341 Installation is in the reverse order of removal. Locations Page 2695 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Diagram Information and Instructions Mass Air Flow Meter: Diagram Information and Instructions Page 273 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Page 2359 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Testing and Inspection Temperature Gauge: Testing and Inspection INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON and check that the receiver gauge needle indicates COOL. c. Ground terminal on the wire harness side connector through a 3.4 W test bulb. d. Turn the ignition switch ON, and check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not as specified, measure the receiver gauge resistance. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. W/ Tachometer Page 79 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 1723 Heater Control Valve: Service and Repair REMOVAL 1. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 2. DISCONNECT WATER VALVE CONTROL CABLE FROM WATER VALVE HINT: At the time of installation, please refer to the following item. For installing the control cable, refer to "INSTALLATION" of HEATER CONTROL ASSEMBLY. 3. DISCONNECT WATER HOSES a. Using pliers, grip the claws of the clip and slide the clip along the hose. b. Disconnect the water hose. HINT: At the time of installation, please refer to the following item. Install the hose clip in the position, as shown in the illustration. 4. REMOVE WATER VALVE Remove the bolt and water valve. INSTALLATION Page 1135 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1492 - Remove the adjusting shim with a small screwdriver and magnetic finger. b. Determine the replacement adjusting shim size by these Formula or Charts: - Using a micrometer, measure the thickness of the removed shim. - Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T...Thickness of removed shim A...Measured valve clearance N...Thickness of new shim Intake: N = T + (A - 0.20 mm (0.008 inch)) Exhaust: N = T + (A - 0.30 mm (0.012 inch)) Page 2688 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2364 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 816 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2152 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2018 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Locations Page 2879 CHART 23 Page 3222 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 19 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2888 CHART 28 Page 2012 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Page 2318 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Page 1156 Underdash Fuses And Relays Page 2069 Specifications Camshaft Gear/Sprocket: Specifications Camshaft Timing Gear Bolt 73.5 Nm (54 ft.lb) Page 1109 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 3069 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Page 2978 b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Torque: 5.4 Nm (55 kgf cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 1785 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 799 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 647 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 42 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Application and ID Valve Spring Shim: Application and ID Page 3038 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 915 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2181 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 771 How To Read Ground Points Page 2873 CHART 18 CHART 19 Page 1310 Coolant: Testing and Inspection INSPECTION 1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The coolant level should be between the "L" and "F" lines. If low, check for leaks and add coolant up to the "F" line. 2. CHECK ENGINE COOLANT QUALITY a. Remove the radiator cap. WARNING: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. b. There should not be any excessive deposits of rust or scales around the radiator cap or radiator filler hole, and the coolant should be free from oil. If excessively dirty, replace the coolant. c. Reinstall the radiator cap. Page 973 Ignition Switch: Testing and Inspection INSPECT IGNITION SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2172 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 831 Step 4 INSPECTION PROCEDURE Page 727 Page 2446 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 803 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 47 Electronic Brake Control Module: Description and Operation CIRCUIT DESCRIPTION This is the power source for the ECU, hence the actuators. Page 2032 Page 2806 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 3044 Vehicle Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 1808 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. DISCONNECT AIR PIPE Remove the 2 bolts and disconnect the air pipe from the fan shroud. 4. DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR 5. REMOVE OIL DIPSTICK GUIDE a. Remove the bolt, dipstick guide and engine wire bracket. b. Remove the O-ring from the dipstick guide. HINT: At the time of installation, please refer to the following items. Use a new O-ring. Page 1086 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1649 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 20 Nm Page 395 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 122 Locations Page 2578 a. Place a new gasket on the throttle body. b. Install the AC valve with the 4 screws. 2. INSTALL THROTTLE BODY Page 3160 Fuel: Service Precautions CAUTION: Your vehicle must use unleaded fuel only. Using leaded fuel will damage the catalytic converter and affect the warranty coverage validity. Page 2671 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1661 - Remove the adjusting shim with a small screwdriver and magnetic finger. b. Determine the replacement adjusting shim size by these Formula or Charts: - Using a micrometer, measure the thickness of the removed shim. - Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T...Thickness of removed shim A...Measured valve clearance N...Thickness of new shim Intake: N = T + (A - 0.20 mm (0.008 inch)) Exhaust: N = T + (A - 0.30 mm (0.012 inch)) Diagrams Page 986 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 377 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 557 Page 2889 CHART 29 Page 1087 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 3014 Transmission Position Switch/Sensor: Electrical Diagrams Page 2568 Page 1281 Fuel Pressure Release: Service and Repair GENERAL PRECAUTIONS 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal removed from The battery. Therefore, if necessary, read the diagnostic trouble code(s) before removing the negative (-) terminal cable from the battery. 2. Do not smoke or work near an open flame when working on the fuel system. FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH PRESSURE FUEL LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: - Put a container under the connection. - Slowly loosen the connection. - Disconnect the connection. - Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use a new gasket. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare and tighten the flare nut by hand. - Using SST, tighten the flare nut to the specified torque. SST 09631-22020 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Page 656 Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR a. Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 20 Nm (200 kg.cm, 14 ft.lb) b. Connect the ECT sensor connector. c. Install the engine wire protector to the 3 brackets. 5. REFILL ENGINE COOLANT Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Specifications Camshaft Gear/Sprocket: Specifications Camshaft Timing Gear Bolt 73.5 Nm (54 ft.lb) Page 2730 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3028 Vehicle Speed Sensor NO.2 Page 3059 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Testing and Inspection Heater Core: Testing and Inspection INSPECT FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. Page 1256 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Disconnect the high-tension cords from the spark plugs. b. Using a 16 mm plug wrench, remove the spark plug. c. Using a spark plug cleaner or wire brush, clean the spark plug. d. Check the spark plug for electrode wear, threads damage and insulator damage. If abnormal, replace the plugs. Recommended spark plugs: ND: K16R-U NGK: BKR5EYA e. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 0.8 mm (0.031 in.) f. Using a 16 mm plug wrench, install the spark plug. Torque: 20 Nm (200 kg.cm, 14 ft.lb) g. Connect the high-tension cords to the spark plugs. Page 3165 Fuel Pressure Release: Service and Repair GENERAL PRECAUTIONS 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal removed from The battery. Therefore, if necessary, read the diagnostic trouble code(s) before removing the negative (-) terminal cable from the battery. 2. Do not smoke or work near an open flame when working on the fuel system. FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH PRESSURE FUEL LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: - Put a container under the connection. - Slowly loosen the connection. - Disconnect the connection. - Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use a new gasket. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare and tighten the flare nut by hand. - Using SST, tighten the flare nut to the specified torque. SST 09631-22020 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Page 2865 CHART 7 Page 2950 Step 2 Step 3 Page 654 Coolant Temperature Sensor/Switch (For Computer): Description and Operation A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the DTC P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). Page 1783 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 867 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Specifications Clutch Fluid: Specifications Type DOT 3 Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm Locations Page 1957 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2296 Page 162 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Testing and Inspection Oil Pressure Sender: Testing and Inspection INSPECT LOW OIL PRESSURE SWITCH a. Disconnect the connector from the switch. b. Check that continuity exists between terminal and ground with the engine stopped. c. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 49 kPa (0.5 kg/Sq.cm, 7.1 psi). If operation is not as specified, replace the switch. Page 1382 Underdash Fuses And Relays Details Locations Headlamp Dimmer Relay: Locations Underhood Fuses And Relays Page 1014 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 3267 a. Place a new gasket on the throttle body. b. Install the AC valve with the 4 screws. 2. INSTALL THROTTLE BODY Page 3148 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Page 1039 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 292 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1168 Underdash Fuses And Relays Page 914 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 675 Crankshaft Position Sensor: Description and Operation Crankshaft position sensor (NE signal) consists of a signal plate and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle and the engine speed by the NE signals. Vapor Pressure Sensor Vapor Pressure Sensor: Testing and Inspection Vapor Pressure Sensor 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V d. Turn the ignition switch to LOCK. e. Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under the following conditions: 1. Apply vacuum (2.0 kPa, 15 mmHg, 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kPa, 15 gf/sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8V d. Reconnect the vacuum hose to the vapor pressure sensor. Page 2381 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 673 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2224 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Testing and Inspection Idle Up Control Valve: Testing and Inspection INSPECTION 1. TURN AIR CONDITIONING SWITCH OFF 2. CHECK IDLE-UP a. Start engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine rpm decreases when the vacuum hose of the air control valve is pinched. d. Check that the engine rpm increases when the hose is released. Page 237 Locations Page 1098 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 121 Underdash Fuses And Relays Details Page 2448 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 3015 Cooling System - Radiator Cap Inspection Procedure Radiator Cap: Technical Service Bulletins Cooling System - Radiator Cap Inspection Procedure ENGINE EG014-05 Title: RADIATOR CAP INSPECTION Models: All Toyota Models March 28, 2005 Introduction The procedure for inspecting the radiator cap has been revised. Please refer to the following procedures when inspecting the radiator cap on all Toyota models. Applicable Vehicles ^ All Toyota and Scion models. Required Equipment Warranty Information Page 2754 Page 1345 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Page 611 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch LOCK. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Page 498 Air Conditioning Switch: Service and Repair REMOVAL REMOVE A/C SWITCH a. Cover the switch with a cloth. b. Using pliers, pull out the switch. INSTALLATION Installation is in the reverse order of removal. Page 2779 Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR a. Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 20 Nm (200 kg.cm, 14 ft.lb) b. Connect the ECT sensor connector. c. Install the engine wire protector to the 3 brackets. 5. REFILL ENGINE COOLANT Page 933 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1067 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 74 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2047 CHART 7 Page 820 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2994 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2882 CHART 25 Page 874 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 261 If continuity is not as specified, replace the switch. Denso Made System Clutch Switch: Testing and Inspection Denso Made System Idle Switch Circuit CIRCUIT DESCRIPTION When the idle switch is turned ON, a signal is sent to the ECU. The ECU uses this signal to correct the discrepancy between the throttle valve position and the actuator position sensor valve to enable accurate cruise control at the set speed. If the idle switch is malfunctioning, problem symptoms also occur in the engine, so also inspect the engine. WIRING DIAGRAM Step 1 Page 345 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2121 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2817 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Description and Operation Passenger Airbag Cutoff Switch: Description and Operation Passenger airbag cutoff switch is mounted on the center cluster finish panel. By turning the passenger airbag cutoff switch to OFF with the ignition key, the passenger airbag system can be disabled.Also, in order to notify the passenger that the passenger airbag is disabled, OFF indicator inside the switch will light up. Page 868 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2149 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1815 Catalytic Converter: Service and Repair 1. REMOVE CONVERTER a. Jack up the vehicle. b. Check that the converter is cool. c. Remove the bolts and nuts at the front and rear of the converter. d. Remove the converter and gasket. 2. REINSTALL CONVERTER a. Place new gaskets on the converter front and rear pipes, and connect the converter the exhaust pipes. b. Torque the bolts and nuts. Torque: 48 Nm (490 kg.cm, 35 ft.lb) Page 2606 Locations Page 706 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1978 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 854 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 1. DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. Page 2144 How To Read Ground Points Page 2156 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 1659 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE PCV HOSES 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. DISCONNECT ENGINE WIRE a. Disconnect these connectors: - w/ A/C: A/C compressor connector - Oil pressure sensor connector - Engine coolant temperature sender gauge connector - Ignition Coil connector b. Disconnect the 4 engine wire clamps and engine wire. 5. REMOVE CYLINDER HEAD COVER Remove the 10 bolts, seal washers, cylinder head cover and gasket. 6. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley clockwise and align its groove with the "0" mark on the timing chain cover. b. Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. 7. INSPECT VALVE CLEARANCE Page 477 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 489 Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation Ford Made System CIRCUIT DESCRIPTION The vehicle speed sensor circuit is sent to cruise control ECU as vehicle speed signal. For each rotation of the shaft, the vehicle speed sensor sends a signal through the combination meter to the cruise control ECU. The ECU calculates the vehicle speed from this pulse frequency. Page 1142 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1471 Crankshaft: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 2677 Oxygen Sensor: Testing and Inspection INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS a. Disconnect the heated oxygen sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: Bank 1 Sensor 1: 11 - 16 ohm at 20 °C (68 °F) Bank 1 Sensor 2: 11 - 16 ohm at 20 °C (68 °F) If resistance is not as specified, replace the heated oxygen sensor. c. Reconnect the heated oxygen sensor connector. Page 2044 CHART 1 Page 1748 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 2026 Applicable Vehicles Page 1387 Underdash Fuses And Relays Details Page 2337 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Disconnect the high-tension cords from the spark plugs. b. Using a 16 mm plug wrench, remove the spark plug. c. Using a spark plug cleaner or wire brush, clean the spark plug. d. Check the spark plug for electrode wear, threads damage and insulator damage. If abnormal, replace the plugs. Recommended spark plugs: ND: K16R-U NGK: BKR5EYA e. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 0.8 mm (0.031 in.) f. Using a 16 mm plug wrench, install the spark plug. Torque: 20 Nm (200 kg.cm, 14 ft.lb) g. Connect the high-tension cords to the spark plugs. Page 3203 Fuel Line Inspection a. Check the fuel lines for cracks or leakage, and all connections for deformation. b. Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. c. Check the fuel tank for deformation, cracks, fuel leakage or tank band looseness. d. Check the filler neck for damage or fuel leakage. e. Hose and pipe connections are as shown in the illustration. If a problem is found, repair or replace the parts as necessary. Locations Power Window Relay: Locations Underhood Fuses And Relays Page 2427 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1948 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1147 Transmission Temperature Sensor/Switch: Service and Repair ON-VEHICLE INSPECTION 1. DISCONNECT ATF TEMPERATURE SENSOR CONNECTOR 2. DISCONNECT OIL COOLER PIPE a. Remove the 3 bolts and clamps. b. Disconnect the oil cooler pipe. 3. REMOVE OIL COOLER ELBOW 4. REMOVE ATF TEMPERATURE SENSOR a. Remove the ATF temperature sensor. b. Remove the O-ring from the ATF temperature sensor. 5. INSTALL ATF TEMPERATURE SENSOR a. Coat a new O-ring with ATF and install it to the ATF temperature sensor. b. Install the ATF temperature sensor. Torque: 15 Nm (155 kgf cm, 11 ft. lbs.) 6. INSTALL OIL COOLER ELBOW 7. CONNECT OIL COOLER PIPE a. Connect the oil cooler pipe Torque: 34 Nm (350 kgf cm, 25 ft. lbs.) b. Install the 3 clamps and bolts. 8. CONNECT ATF TEMPERATURE SENSOR NOTICE: Be careful not to twist the wire harness. Page 3245 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 433 Clutch Switch: Description and Operation Denso Made System Idle Switch Circuit CIRCUIT DESCRIPTION When the idle switch is turned ON, a signal is sent to the ECU. The ECU uses this signal to correct the discrepancy between the throttle valve position and the actuator position sensor valve to enable accurate cruise control at the set speed. If the idle switch is malfunctioning, problem symptoms also occur in the engine, so also inspect the engine. Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Locations Starter Relay: Locations Underhood Fuses And Relays Page 625 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1237 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Locations Page 529 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2267 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2927 Page 2969 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 3141 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 1960 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the engine wire protector from the 3 brackets. b. Disconnect the ECT sensor connector. c. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Page 320 Page 839 How To Read Ground Points Ford Made System Cruise Control Module: Testing and Inspection Ford Made System CIRCUIT DESCRIPTION The ECU power source supplies power to the actuator and sensors, etc.. When terminal GND and the cruise control ECU case are grounded. WIRING DIAGRAM Step 1 Page 348 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1356 NOTICE: Check that the valve of the SST is in the open position. d. Bleed the power steering system. e. Start the engine and run it at idle. f. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) g. With the engine idling, close the valve of the SST and observe the reading on the SST Minimum fluid pressure: 8,336 kPa (85 kgf/cm2,1,209 psi) NOTICE: ^ Do not keep the valve closed for more than 10 seconds. ^ Do not let the fluid temperature become too high. h. With the engine idling, open the valve fully. i. Measure the fluid pressure at engine speeds of 1,000 rpm and 3,000 rpm. Difference fluid pressure: 490 kPa (5 kgf/cm2, 71 psi) or less NOTICE: Do not turn the steering wheel. Page 2266 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Specifications Exhaust Manifold: Specifications Exhaust Manifold Fasteners 49 Nm (36 ft.lb) Heat Insulator 5.5 Nm (48 in.lb) Page 853 Vehicle Speed Sensor: Testing and Inspection INSPECT VEHICLE SPEED SENSOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b. Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c. Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be performed 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. Page 297 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2937 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1911 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2811 Intake Air Temperature Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1999 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2063 CHART 24 Page 475 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2746 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 319 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Diagram Information and Instructions Mass Air Flow Meter: Diagram Information and Instructions Page 2436 Diagram Information and Instructions Idle Air Control Valve: Diagram Information and Instructions Page 2732 Page 2940 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2545 Part 2 Of 2 Diagram Information and Instructions Cruise Control Module: Diagram Information and Instructions Diagram Information and Instructions Mass Air Flow Meter: Diagram Information and Instructions Page 801 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2805 How To Read Ground Points Page 2656 CHART 28 Page 2598 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 1320 Fluid - A/T: Testing and Inspection 1. Operate vehicle, allow transmission fluid temperature to reach 158-176 °F. 2. Position vehicle on level surface, apply parking brake. 3. Allow engine to idle, depress brake pedal, then move shift lever through all positions. 4. Remove transaxle dipstick, wipe clean, then replace. 5. Remove again, then check fluid level in HOT range. NOTICE: Do not overfill. (a) Check the fluid condition. If the fluid smells burnt or is black, replace it. (b) Replace the ATF. (1) Remove the drain plug and drain the fluid. (2) Reinstall the drain plug securely. 7. On A340D units: Dry capacity is 6.9 US quarts. Drain and Refill: 2.4 Liters (2.5 US qts, 2.1 Imp. qts.) 8. On A340E units: Dry capacity is 7.6 US quarts. Drain and Refill: 1.6 Liters (1.7 US qts, 1.4 Imp. qts.) 9. On A340F units: Dry capacity 1996 9.3 US quarts. Dry capacity 1997-99 10.7 US quarts. Drain and Refill: 2.0 Liters (2.1 US qts, 1.8 Imp. qts.) 10. On A340H units, dry capacity for transaxle and transfer is 10.9 US quarts. Page 284 Acceleration/Deceleration Sensor: Description and Operation CIRCUIT DESCRIPTION This sensor detects deceleration on the vehicle. The sensor signal is used in ABS control. If the sensor functions abnormally. The ECU cuts off current to the ABS control (solenoid) relay and prohibit ABS control. Page 2866 CHART 8 CHART 9 Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Page 1136 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 891 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 3023 Step 4 INSPECTION PROCEDURE Page 3098 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 409 Brake Switch (Cruise Control): Testing and Inspection Ford Made System CIRCUIT DESCRIPTION When the brake is on, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP- of the ECU, and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. If the harness connected to terminal STP- has an open circuit, terminal STP- will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch is cut mechanically by the stop light switch, turning the cruise control off. WIRING DIAGRAM Step 1 Page 2371 Mass Air Flow Meter: Description and Operation The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Page 1609 b. Apply seal packing to the oil pan as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 inch) opening or 3 - 4 mm (0.012 0.016 inch) opening. HINT: Avoid applying an excessive amount to the surface. ^ Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied. ^ Immediately remove nozzle from the tube and reinstall cap. c. Install the oil pan with the 16 bolts and 2 nuts. Torque: 12.5 Nm (130 kgf.cm, 9 ft. lbs.) 13. INSTALL FLYWHEEL HOUSING UNDER COVER AND DUST SEAL 14. 2WD: INSTALL STIFFENER PLATES Torque: 37 Nm (380 kgf.cm, 27 ft. lbs.) 15. INSTALL CRANKSHAFT POSITION SENSOR Install a new O-ring. Torque: 8.5 Nm (85 kgf.cm,74 inch lbs.) 16. INSTALL GENERATOR, ADJUSTING BAR AND BRACKET a. Install the bracket with the 3 bolts. Torque: Bolt A: 74.5 Nm (760 kgf.cm, 55 ft. lbs.) Bolt B: 18 Nm (185 kgf.cm, 13 ft. lbs.) b. Install the adjusting bar with the bolt. Torque: 63.5 Nm (650 kgf.cm, 47 ft. lbs.) c. Install the generator with the pivot bolt and lock bolt. 17. w/ A/C: INSTALL A/C COMPRESSOR AND BRACKET a. Install the A/C compressor bracket with the 4 bolts. Torque: 44 Nm (440 kgf.cm, 32 ft. lbs.) b. Install the A/C compressor with the 4 bolts. Torque: 25 Nm (250 kgf.cm, 18 ft. lbs.) 18. INSTALL CYLINDER HEAD ASSEMBLY 19. INSTALL WATER PUMP PULLEY, FAN WITH FLUID COUPLING AND DRIVE BELT FOR GENERATOR 20. 4WD: INSTALL FRONT DIFFERENTIAL AND DRIVE SHAFTS ASSEMBLY 21. FILL WITH ENGINE OIL 22. START ENGINE AND CHECK FOR LEAKS 23. INSTALL ENGINE UNDER COVER 24. VEHICLE ROAD TEST Check for abnormal noise, shock slippage, correct shift points and smooth operation. 25. RECHECK ENGINE COOLANT AND ENGINE OIL LEVEL Page 2705 Step 6 Step 7 INSPECTION PROCEDURE Page 1869 Step 2 Step 3 Step 4 Step 5 Page 2799 Crankshaft Position Sensor: Testing and Inspection NOTE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10 ° C (14 ° F) to 50 °C (122 °F) and "Hot" is from 50 °C (122°F) to 100 °C (212 °F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (NE(+) and NE(-)): Cold: 1,630 - 2,740 Ohms Hot: 2,065 - 3,225 Ohms If the resistance is not as specified, replace the crankshaft position sensor. Page 429 Clutch Switch: Electrical Diagrams Page 1116 Step 4 INSPECTION PROCEDURE Locations Page 1754 3. DISCONNECT AIR PIPE Remove the 2 bolts and disconnect the air pipe. 4. DISCONNECT UPPER RADIATOR HOSE 5. DISCONNECT RADIATOR RESERVOIR HOSE 6. DISCONNECT LOWER RADIATOR HOSE 7. REMOVE NO.2 FAN SHROUD 8. A/T: DISCONNECT OIL COOLER HOSES 9. REMOVE RADIATOR Remove the 4 bolts and radiator. Torque: 12.5 Nm (125 kgf.cm, 9 ft. lbs.) HINT: At the time of installation, please refer to the following items. Insert the tabs of the radiator support through the radiator service holes. DISASSEMBLY 1. REMOVE NO.1 FAN SHROUD Remove the 4 bolts and fan shroud. Page 1213 VZN195L model If the steering axis inclination is not within the specified value, after the camber and caster have been correctly adjusted, recheck the steering knuckle and front wheel for bearing or looseness. 4. ADJUST CAMBER AND CASTER a. Loosen the front and/or rear adjusting cam nuts. Page 829 Transmission Position Switch/Sensor: Testing and Inspection Ford Made CIRCUIT DESCRIPTION When the shift position is put in positions except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM Step 1 Page 209 Air Bag Control Module: Description and Operation The airbag sensor assembly is mounted on the floor inside the center cluster. The airbag sensor assembly consists of a airbag sensor, safing sensor, diagnosis circuit, ignition control and drive circuit, etc.. It receives signals from the airbag sensor assembly and judges whether the SRS must be activated or not and diagnosis system malfunctions. Page 2946 Locations Actuator Relay: Locations Underhood Fuses And Relays Page 543 Underdash Fuses And Relays Page 1870 Step 6 Step 7 INSPECTION PROCEDURE Page 2510 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1108 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1286 Oil Filter: Tools and Equipment Toyota Oil Filter Wrench Set AST tool# TOY 300 This set includes our tool numbers TOY640, TOY730, and M0219. With the TOY300 you have every gas engine Toyota/Lexus model covered between 1980 and 2009. - Covers all Toyota and Lexus vehicles 1980-2009, based on factory filters. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Kit Contains the Following Tools: TOY 640 - Toyota Oil Filter Wrench Page 2795 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1596 Page 2721 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2409 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Locations Page 1491 a. Check only the valves indicated. - Using a thickness gauge, measure the clearance between the valve lifter and camshaft. - Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake: 0.15 - 0.25 mm (0.006 - 0.010 inch) Exhaust: 0.25 - 0.35 mm (0.010 - 0.014 inch) b. Turn the crankshaft pulley 1 revolution (360°) and align its groove with timing mark "O" of the timing chain cover. c. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 8. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. - Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. - Position the notch of the valve lifter toward the spark plug side. - Using Special Service Tool (SST) (A), press down the valve lifter and place (SST) (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) HINT: ^ Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration. Page 1036 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Standard Value of ECM Terminals Engine Control Module: Testing and Inspection Standard Value of ECM Terminals Part 1 Of 2 Page 2837 Page 192 a. Apply battery positive voltage across terminals STA and E1. b. Using an ohmmeter, check that there is continuity between terminals +B and FP. c. Apply battery positive voltage across terminals +B and FC. d. Check that there is continuity between terminals +B and FP. If operation is not as specified, replace the relay. 5. REINSTALL CIRCUIT OPENING RELAY 6. REINSTALL LOWER FINISH NO.1 PANEL Page 1679 Coolant: Fluid Type Specifications Coolant Type "Toyota Long Life Coolant" or Equivelant Ethylene-Glycol Coolant Do Not use alcohol type antifreezs or plain water alone. Page 294 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1175 Page 370 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 111 Underdash Fuses And Relays Details Page 661 How To Read Ground Points Page 1954 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 176 Part 2 Of 2 Page 1972 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 851 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2731 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 704 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2465 How To Read Ground Points Page 1493 Locations Page 2108 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2684 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2924 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1719 Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR a. Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 20 Nm (200 kg.cm, 14 ft.lb) b. Connect the ECT sensor connector. c. Install the engine wire protector to the 3 brackets. 5. REFILL ENGINE COOLANT Locations Horn Relay: Locations Underhood Fuses And Relays Page 610 Mass Air Flow Meter: Description and Operation The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Page 836 Vehicle Speed Sensor NO.2 Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Page 3248 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2932 How To Read Ground Points Page 1267 Page 2176 Vapor Pressure Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 682 How To Read Ground Points Page 1914 Page 793 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2060 Page 2747 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Testing and Inspection Instrument Panel Relay: Testing and Inspection INSPECT BULB CHECK RELAY OPERATION a. Connect the positive (+) lead from the battery to terminal C through a 1.4 W test bulb and the negative (-) lead to terminal B, check that the test bulb does not light up. b. Connect the positive (+) lead from the battery to terminal A and check that the test bulb lights up. If operation is not as specified, replace the relay. Testing and Inspection Door Switch: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY a. Check that continuity exists between terminal and the switch body in the ON position (switch pin released : opened door). b. Check that no continuity exists between terminal and the switch body in the OFF position (switch pin pushed in : closed door). If operation is not as specified, replace the switch Page 454 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 998 Passenger Airbag Cutoff Switch: Testing and Inspection 1. INSPECT PASSENGER AIRBAG CUTOFF SWITCH CONTINUITY HINT: Release the airbag activation prevention mechanism of the passenger airbag cutoff switch connector on the airbag sensor assembly side. If continuity is not as specified, replace the switch. 2. INSPECT PASSENGER AIRBAG CUTOFF INDICATOR OPERATION a. Check that continuity exists between 6 and 7. b. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 4. c. Check that the indicator light lights up. If the operation is not as specified, replace the indicator. Fuel System - Fuel Injector Cleaning Procedure Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Cleaning Procedure PRODUCT GENERAL INFORMATION PG011-05 REVISED October 13, 2005 Title: FUEL INJECTOR CLEANING Models: '90 - '06 Toyota & Scion Models With Port Electronic Fuel Injection TSB REVISION NOTICE: ^ June 9, 2006: In the Required Tools & Material section, part numbers have been updated (TYG S-Line Device and Toyota Adaptor Pak), and the note with ordering information has been updated. Previous versions of this TSB should be discarded. Introduction Due to fuel quality concerns, some Toyota and Scion vehicles with Port Electronic Fuel Injection may experience clogged or blocked fuel injectors. The following procedure has been developed to clean the fuel injectors. Applicable Vehicles: ^ All 1990 - 2006 Toyota and Scion models equipped with Port Electronic Fuel Vehicles Injection (EFI). Required Tools & Material Warranty Information Repair Procedure 1. If the fuel injector nozzles are visibly blocked or if the injectors do NOT pass the fuel injector volume test, complete the fuel injector power flush using the following instructions: A. Before an injector cleaning is performed, it is recommended that the following items be cleaned with Toyota Throttle Plate Cleaner (P/N 00289-1TP00): ^ Idle air control device ^ Throttle plate (both sides if possible) ^ Throttle body B. Bring the engine to operating temperature. C. Disconnect the fuel pump electrical connector. Page 2178 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2083 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 301 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2720 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 905 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch LOCK. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Page 606 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 943 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Capacity Specifications Coolant: Capacity Specifications With M/T 8.3 L (8.8 US qts.) With A/T 8.2 L (8.7 US qts.) Page 3321 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2784 How To Read Ground Points Page 389 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2513 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1170 Parts Location Locations Page 2954 Step 4 INSPECTION PROCEDURE Page 2480 Starter Signal: Testing and Inspection CIRCUIT DESCRIPTION When the engine is cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after-start injection control. WIRING DIAGRAM INSPECTION PROCEDURE HINT: This diagnostic chart is based on the premise that the engine is cranked normally. If the engine is not cranked, proceed to the Diagnosis By Symptom. Page 904 Mass Air Flow Meter: Description and Operation The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Page 2341 Compression Check: Testing and Inspection INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. REMOVE SPARK PLUGS 5. CHECK CYLINDER COMPRESSION PRESSURE a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle c. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. d. Repeat steps a. through c. for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,230 kPa (12.5 kgf/cm2, 178 psi) or more Minimum pressure: 880 kPa (9.0 kgf/cm2, 127 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less e. If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps a. through c. for cylinders with low compression. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damage. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 6. REINSTALL SPARK PLUGS Torque: 19 Nm (200 kgf.cm, 14 ft. lbs.) 7. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 8. REINSTALL INTAKE AIR CONNECTOR Ford Made System Clutch Switch: Description and Operation Ford Made System Idle Switch Circuit CIRCUIT DESCRIPTION When the idle switch is turned ON, a signal is sent to the ECU. The ECU uses this signal to correct the discrepancy between the throttle valve position and the actuator position sensor valve to enable accurate cruise control at the set speed. If the idle switch is malfunctioning, problem symptoms also occur in the engine, so also inspect the engine. Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Page 1027 How To Read Ground Points Testing and Inspection Headlamp Dimmer Switch: Testing and Inspection INSPECT LIGHT CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2899 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1716 Page 782 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 339 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1117 Transmission Position Switch/Sensor: Testing and Inspection Ford Made CIRCUIT DESCRIPTION When the shift position is put in positions except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM Step 1 Page 955 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3045 Vehicle Speed Sensor: Testing and Inspection INSPECT VEHICLE SPEED SENSOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b. Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c. Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be performed 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. Specifications Firing Order: Specifications Firing order: 1-3-4-2 Page 991 Page 3357 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 619 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2086 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1419 Wheel Hub (Locking): Service and Repair REMOVAL 1. REMOVE FREE WHEEL HUB COVER Page 3144 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake 0.15-0.25 mm (0.006-0.010 in) Exhaust 0.25-0.35 mm (0.010-0.014 mm) Page 3180 Fuel Injector: Testing and Inspection On-Vehicle 1. INSPECT INJECTOR OPERATION Check operation sound from each injector. a. With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine speed. b. If you have no sound scope, you can check the injector transmission operation with your finger. If no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the ECM. 2. INSPECT INJECTOR RESISTANCE a. Remove the throttle body. b. Disconnect the injector connectors. c. Using an ohmmeter, measure the resistance between the terminals. Resistance: 12 - 16 ohms at 20 °C (68 °F) If the resistance is not as specified, replace the injector. d. Reconnect the injector connectors. e. Reinstall the throttle body. Page 1650 Spark Plug: Application and ID Recommended Spark Plugs ND K16R-U NGK BKR5EYA Page 2733 Mass Air Flow Meter: Description and Operation The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Page 978 How To Read Ground Points Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 1799 Page 3062 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 1709 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2087 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3223 Fuel Gauge Sender: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 979 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Service and Repair Valve: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 2836 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Page 3001 How To Read Ground Points Page 2852 A/F and 02 Sensor Identification Locations Page 2329 Ignition Cable: Testing and Inspection INSPECT HIGH-TENSION CORDS a. Remove the air cleaner cap and MAF meter assembly. b. Remove the intake air connector. c. Disconnect the high-tension cords from the spark plugs. NOTE: Pulling on or bending the cords may damage the conductor inside. d. Disconnect the high-tension cords from the ignition coils. 1. Using a screwdriver, lift up the lock claw and disconnect the holder from the ignition coils. 2. Disconnect the high-tension cord at the grommet. NOTE: Pulling on or bending the cords may damage the conductor inside. - Do not wipe any of the oil from the grommet after the high- tension cord is disconnected. e. Using an ohmmeter, measure the resistance. Maximum resistance: 25 kohms per cord Testing and Inspection Washer Fluid Level Switch: Testing and Inspection INSPECT WASHER LEVEL SWITCH a. Check that no continuity exists between terminals with the switch OFF (float up). b. Check that continuity exists between terminals with the switch ON (float down). If operation is not as specified, replace the switch. Page 1926 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Specifications Wheel Speed Sensor: Specifications Speed Sensor Installation Bolt 71 in.lb Front Speed Sensor Harness To: Upper Arm 71 in.lb Side Rail 108 in.lb Rear Speed Sensor Harness To: Axle Housing 108 in.lb Fuel Tank 108 in.lb Side Rail 108 in.lb Page 2057 Page 663 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1037 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Denso Made Transmission Position Switch/Sensor: Testing and Inspection Denso Made CIRCUIT DESCRIPTION When the shift position is put in positions except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM Step 1 Page 2887 Page 1066 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1282 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Page 1766 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Plastic Cap, 108 kPa 1. Remove coolant and any foreign material on 0-ring "A." 2. Check that 0-ring "A" is not deformed, cracked, or swollen. 3. Apply engine coolant to 0-ring "A" and rubber point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 4. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 Page 1083 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3234 Part 1 Of 4 Page 2129 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch go on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM. Terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in D position. When the shift position is except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. Locations Page 817 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1937 Page 2416 Brake Signal: Testing and Inspection Automatic Transmission CIRCUIT DESCRIPTION The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition, when brakes are suddenly applied. When the brake pedal is depressed, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. DETECTING CONDITIONS WIRING DIAGRAM Step 1 Page 382 Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR a. Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 20 Nm (200 kg.cm, 14 ft.lb) b. Connect the ECT sensor connector. c. Install the engine wire protector to the 3 brackets. 5. REFILL ENGINE COOLANT Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Page 521 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Locations Shift Interlock Relay: Locations Underhood Fuses And Relays Page 2122 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 556 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 463 Cruise Control Switch: Description and Operation Ford Made CIRCUIT DESCRIPTION This circuit carries the SET/COAST, RESUME/Accel and CANCEL signals (each voltage) to the ECU. Page 419 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2723 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2370 Page 1162 Service Hints F 6 4WD ECU 16-GROUND : Always approx. 12 Volts 8-GROUND: Always continuity 5-GROUND: 4 pulses with 1 rotation 15-GROUND : 2 Volts or less with 2-4 select SW ON 14-GROUND : 2 Volts or less with detection SW (Transfer L4 position) ON and transfer shift lever at L4 position T 3 2-4 SELECT SW 1-2 : Closed with 2-4 select SW ON P 1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW] 4-7 : Closed with A/T shift lever at P position Splice Points Page 2670 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. ABS/TCS - Zero Point Calibration Information Alignment: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 527 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 776 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2741 How To Read Ground Points Page 1139 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2690 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2125 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1100 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1927 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2881 CHART 24 Page 1829 Applicable Warranty*: This repair is covered under the Federal Emissions Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in service date. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 354 Wheel Speed Sensor: Service and Repair Rear HINT: Pre runner is the described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB REMOVAL 1. REMOVE SPEED SENSOR a. Disconnect the speed sensor connector, and pull out the sensor wire harness with grommet. b. Remove the 5 resin clips, 2 clamp set bolts and 2 nuts holding the sensor wire harness from the side rail, fuel tank and axle housing. Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.) c. Remove the 2 mounting bolts and speed sensor. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. - There are no objects on the sensor or the part of the axle end to which the sensor is to be installed. - The sensor is installed flat against the axle end when you tighten the bolt. - When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. NOTICE: After installation, check the speed sensor signal. Page 36 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2470 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 3060 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3383 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2103 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2077 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1597 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE OIL 3. 4WD: REMOVE FRONT DIFFERENTIAL AND DRIVE SHAFTS ASSEMBLY 4. REMOVE DRIVE BELT FOR GENERATOR, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY 5. REMOVE CYLINDER HEAD ASSEMBLY 6. w/ A/C: DISCONNECT A/C COMPRESSOR AND BRACKET a. Remove the 4 bolts, and disconnect the compressor from the bracket. HINT: Put aside the compressor, and suspend it. Page 1778 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2403 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2020 Knock Sensor: Description and Operation The knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 392 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm Page 2030 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 3355 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 67 How To Read Ground Points Page 2672 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1765 Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Compact Cap, 108 kPa 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A" and "B" are not deformed, cracked, or swollen. 3. Check that points "B" and "C" are not stuck together. 4. Apply engine coolant to point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01 (09231-10110-01) 6. When using the radiator cap tester, tilt it more than 30 degrees. Page 3118 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 2542 Engine Control Module: Description and Operation DESCRIPTION The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to accomplish this control, the ECM relies on the input from a variety of engine operation sensors. The ECM compares input signals with those stored in memory to determine what steps should be taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM outputs the necessary signals to the fuel system, ignition system, emission control systems, etc.. Battery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is OFF for use by the DTC memory and air-fuel ratio adaptive control value memory, etc. Page 1805 Water Pump: Diagrams Page 665 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 73 Cruise Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2247 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Diagram Information and Instructions Differential Lock Switch: Diagram Information and Instructions Page 847 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1669 WATER PUMP AND RELATED COMPONENTS Page 1749 Radiator: Diagrams Page 2473 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 640 How To Read Ground Points Page 3235 Part 2 Of 4 Page 2710 Underdash Fuses And Relays Details Page 1980 Crankshaft Position Sensor: Description and Operation Crankshaft position sensor (NE signal) consists of a signal plate and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle and the engine speed by the NE signals. Page 896 Mass Air Flow Meter: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1090 Transmission Mode Switch: Testing and Inspection CIRCUIT DESCRIPTION The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock-up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position and other various sensors, the ECM switches the solenoid valves ON and OFF, and controls the transmission gear change and the lock-up clutch operation. WIRING DIAGRAM Page 26 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 724 A/F and 02 Sensor Identification Page 2201 Mass Air Flow Meter: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2600 Knock Sensor: Description and Operation The knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 254 Power Window Relay: Testing and Inspection INSPECT POWER MAIN RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 2175 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 689 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Page 734 Connecting Rod Connecting Rod: Specifications Connecting Rod DIMENSIONS Clearance: Oil: Standard ................................................................................................................................................ 0.030 0.055 mm (0.0012 - 0.0022 inch) U/S 0.25 ................................................................................................................................................ 0.031 0.071 mm (0.0012 - 0.0026 inch) Maximum ........................................................................................ ................................................................................... 0.10 mm (0.0039 inch) Piston Pin Oil: Standard ................................................................................................................................................ 0.005 0.011 mm (0.0002 - 0.0004 inch) Maximum ........................................................................................ ................................................................................. 0.015 mm (0.0006 inch) Thrust: STD ....................................................................................................................................................... 0.160 - 0.312 mm (0.0063 - 0.0123 inch) Maximum ............................................................................ ............................................................................................... 0.35 mm (0.0138 inch) Diameter: Big End Inside: Standard: Mark 4 ......................................................................................................................................... 56.000 - 56.006 mm (2.2047 - 2.2050 inch) Mark 5 ......................................................................................................................................... 56.006 56.012 mm (2.2050 - 2.2052 inch) Mark 6 ......................................................................................................................................... 56.012 56.018 mm (2.2052 - 2.2054 inch) Undersize: 0.25 .............................................................................................................................................. 56.000 - 56.018 mm (2.2047- 2.2054 inch) Bolt Outside: Standard .................................................................................................................................................... 7.80 - 7.90 mm (0.3071 - 0.3110 inch) Minimum ......................................................................................... .................................................................................. 7.60 mm (0.2992 inch) Bushing Inside: Standard (New) ...................................................................................................................................24.008 - 24.017 mm (0.9452 - 0.9455 inch) Piston Pin: Standard (New) ................................................................................................................................. 24.000 - 24.009 mm (0.9449 - 0.9452 inch) Rod: Out-Of-Alignment: Maximum Per 100 mm (3.94 inch) .................................................................................................................................... 0.05 mm (0.0020 inch) Twist: Maximum Per 100 mm (3.94 inch) .................................................................................................................................... 0.15 mm (0.0059 inch) Thickness: Bearing Center Wall: Standard: Mark 4 ............................................................................................................................................. 1.482 - 1.485 mm (0.0583 - 0.0585 inch) Mark 5 ............................................................................................................................................. 1.485 1.488 mm (0.0585 - 0.0586 inch) Mark 6 ............................................................................................................................................. 1.488 1.491 mm (0.0586 - 0.0587 inch) Undersize: 0.25 ................................................................................................................................................. 1.601 - 1.607 mm (0.0630 - 0.0633 inch) TIGHTENING SPECIFICATIONS Rod Cap To Connecting Rod 1st Pass ............................................................................................................................................... ............................................ 45 Nm (33 ft. lbs.) 2nd Pass ................................................................... .................................................................................................................... Turn Additional 90° Page 2617 Applicable Vehicles Page 1426 Wheel Fastener: Service and Repair Rear HUB BOLT REPLACEMENT 1. Remove wheel and brake drum. 2. Remove hub bolt. Using SST, 09650-17011 3. Install hub bolt. Install a washer and nut to a new hub bolt as shown and install the hub bolt with torquing the nut. 4. Install brake drum and wheel. Torque to 110 Nm (83 ft. lbs.) Page 2591 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 3146 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Testing and Inspection Daytime Running Lamp Relay: Testing and Inspection Terminal Identification INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side. If circuit is as specified, perform inspections. Page 2102 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 439 Clutch Switch: Testing and Inspection Ford Made System Idle Switch Circuit CIRCUIT DESCRIPTION When the idle switch is turned ON, a signal is sent to the ECU. The ECU uses this signal to correct the discrepancy between the throttle valve position and the actuator position sensor valve to enable accurate cruise control at the set speed. If the idle switch is malfunctioning, problem symptoms also occur in the engine, so also inspect the engine. WIRING DIAGRAM Step 1 Page 784 Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Page 2790 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2777 Coolant Temperature Sensor/Switch (For Computer): Description and Operation A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the DTC P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). Page 644 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 3107 Page 612 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. Page 818 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2863 CHART 2 CHART 3 CHART 4 Page 1494 - Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch). c. Install a new adjusting shim. - Place a new adjusting shim on the valve lifter. Page 2148 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 3009 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1868 Engine Control Module: Testing and Inspection Related Diagnostic Procedures CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Step 1 Page 2891 Ford Made System Brake Switch (Cruise Control): Description and Operation Ford Made System CIRCUIT DESCRIPTION When the brake is on, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP- of the ECU, and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. If the harness connected to terminal STP- has an open circuit, terminal STP- will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch is cut mechanically by the stop light switch, turning the cruise control off. Specifications Crankshaft: Specifications Crankshaft Thrust Clearance Standard 0.020-0.220 mm Maximum 0.30 mm Thrust Washer Thickness 2.440-2.490 mm Crankshaft Runout Maximum Circle Runout 0.03 mm Main Journal Diameter No.3 - Standard 59.981-59.994 mm Others - Standard 59.987-60.000 mm No. 3 - U/S 0.25 59.740-59.750 mm Others - U/S 0.25 59.745-59.755 mm Crank Pin Diameter Standard 52.987-53.000 mm U/S 0.25 52.745-52.755 mm Main Journal and Crank Pin Maximum Taper 0.005 mm Maximum Out-of-Round 0.005 mm ABS/TCS - Zero Point Calibration Information Yaw Rate Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 2091 Oxygen Sensor: Testing and Inspection INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS a. Disconnect the heated oxygen sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: Bank 1 Sensor 1: 11 - 16 ohm at 20 °C (68 °F) Bank 1 Sensor 2: 11 - 16 ohm at 20 °C (68 °F) If resistance is not as specified, replace the heated oxygen sensor. c. Reconnect the heated oxygen sensor connector. Service and Repair Oil Filter: Service and Repair For information regarding the service and repair of this component, please refer to Oil; Service and Repair. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Page 2537 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 184 Underdash Fuses And Relays Details Page 473 How To Read Ground Points Page 2259 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1215 3. Mark the alignment value measured when the vehicle was non-loaded on the adjustment chart. Example: Camber: -0° 10' (-0.17°) Caster: 1°40' (1.67°) 4. As shown in the chart, read the distance from the measured value to the standard value, and adjust the front and/or rear adjusting cams accordingly. Example: Front cam: - (Shorter) 2.8 Rear cam: - (Shorter) 2.8 d. Torque the front and/or rear adjusting cam nuts. Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.) Measuring Point Reference 5. INSPECT TOE-IN Toe-in: If the toe-in is not within the specified value, adjust the rack ends. 6. ADJUST TOE-IN AND WHEEL ANGLE HINT: First, check or adjust the lengths of the rack ends, then adjust the toe-in. Rack end length difference: 1.5 mm (0.059 inch) or less a. Remove the 2 clips. Page 2922 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Testing and Inspection Interior Light Switch: Testing and Inspection INSPECT ROOM LIGHT SWITCH CONTINUITY a. Disconnect the connector from room light switch. b. Turn the room light switch ON, check that continuity exists between terminal 2 and body ground. c. Turn the room light switch to DOOR, check that there is continuity between terminals 1 and 2. If operation is not as specified, replace the switch. Page 2497 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit A/T - Delayed Upshift To O/D With Cruise Engaged Cruise Control Module: Customer Interest A/T - Delayed Upshift To O/D With Cruise Engaged BULLETIN NUMBER: EL004-00 DATE: April 14, 2000 TITLE: DELAYED UPSHIFT TO OVERDRIVE WITH CRUISE CONTROL ENGAGED MODELS: '98 - '99 Tacoma INTRODUCTION A revised cruise control ECU is available for 1998-1999 Tacoma trucks with automatic transmissions. While cruise control is engaged, the new ECU improves the upshift delay from 3rd to 4th gear after the vehicle comes over the crest of a hill. To correct the concern, replace the cruise control ECU and perform the cable adjustment procedure as shown in this bulletin. APPLICABLE VEHICLES: 1998 - 1999 (4 cylinder) Tacoma Trucks with automatic transmissions produced before the VIN's listed in the illustration. PRODUCTION CHANGE INFORMATION PARTS INFORMATION WARRANTY INFORMATION APPLICABLE WARRANTY*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. REPAIR PROCEDURE: Page 508 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL 1. REMOVE EVAPORATOR 2. REMOVE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the pressure switch. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) HINT: Lock the switch mounted on the tube with an open end wrench, being careful not to deform the tube and remove the switch. At the time of installation, please refer to the following item. Lubricate a new O-ring with the compressor oil and install the switch. INSTALLATION Installation is in the reverse order of removal. Testing and Inspection Brake Light Switch: Testing and Inspection w/o Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. W/ Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 3198 a. Apply battery positive voltage across terminals STA and E1. b. Using an ohmmeter, check that there is continuity between terminals +B and FP. c. Apply battery positive voltage across terminals +B and FC. d. Check that there is continuity between terminals +B and FP. If operation is not as specified, replace the relay. 5. REINSTALL CIRCUIT OPENING RELAY 6. REINSTALL LOWER FINISH NO.1 PANEL Page 2788 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2373 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. Page 2488 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2650 CHART 25 Page 2389 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2854 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 2230 Page 953 How To Read Ground Points Page 1592 Page 2278 Ignition Switch: Testing and Inspection INSPECT IGNITION SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2401 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1183 a. Connect the positive (+) lead from the battery to terminal 2 and the negative (-) lead to terminal 3. b. Connect the positive (+) lead from the ohmmeter to terminal 5 and the negative (-) lead to terminal 4. c. Check that there is continuity between terminals 4 and 5. d. Connect the positive (+) lead from the battery to terminal 3 and the negative (-) lead to terminal 2. e. Connect the positive (+) lead from the ohmmeter to terminal 6 and the negative (-) lead to terminal 4. f. Check that there is continuity between terminal 4 and 6. If continuity is not as specified, replace the actuator assembly. 5. INSPECT NO.1 VEHICLE SPEED SENSOR. 6. INSPECT 4WD INDICATOR LAMP Check the combination meter. 7. w/ One touch 2-4 selector system: INSPECT 4WD CONTROL ECU Connect the wire harness side connector to the ECU and inspect wire harness side connector from the back side, as shown. Page 1602 21. REMOVE BALANCE SHAFT DRIVE GEAR, SHAFT, NO.2 TIMING CHAIN AND NO.2 CRANKSHAFT TIMING SPROCKET a. Remove the bolt from the balance shaft drive gear. b. Remove the balance shaft drive gear with the shaft. c. Remove the No.2 timing chain with the No.2 crankshaft timing sprocket. 22. REMOVE NO.4 VIBRATION DAMPER Remove the 2 bolts and No.4 damper. INSPECTION 1. INSPECT TIMING CHAINS, TIMING GEARS AND TIMING SPROCKETS a. Measure the length of 16 links with the chain fully stretched. Maximum chain elongation: No.1 Timing chain: 147.5 mm (5.807 inch) 3RZ-FE: No.2 Timing chain: 123.6 mm (4.866 inch) If the elongation is greater than maximum, replace the chain. HINT: Make the same measurements pulling at 3 or more places selected at random. b. Wrap the chain around the timing gear and timing sprocket. Page 2426 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 1724 Installation is in the reverse order of removal. Page 2775 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 1606 c. Install No.2 damper with the bolt. Torque: 27 Nm (270 kgf.cm, 20 ft. ft. lbs.) d. Remove a pin from the No.2 chain tensioner and free the plunger. 4. 2RZ-FE: INSTALL OIL JET Install a new gasket and the oil jet with the bolt. Torque: 18 Nm (185 kgf.cm, 13 ft. lbs.) 5. 2RZ-FE: INSTALL CRANKSHAFT POSITION SENSOR ROTOR Install the rotor to the crankshaft with the front mark (cavity) of the rotor facing forward. 6. INSTALL NO.1 TIMING CHAIN TENSIONER SLIPPER AND NO.1 VIBRATION DAMPER a. Install the No.1 damper with the bolt and nut. Torque: 29 Nm (300 kgf.cm, 22 ft. lbs.) b. Install the slipper with the bolt. Torque: 27 Nm (270 kgf.cm, 20 ft. lbs.) c. Check that the slipper moves smoothly. 7. INSTALL CRANKSHAFT TIMING GEAR Page 1975 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 651 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 726 Applicable Vehicles Page 777 Oxygen Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1033 Overdrive Switch: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3303 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3064 Vapor Pressure Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2653 Page 2530 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 270 How To Read Ground Points Page 802 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Locations EFI Main Relay: Locations Underhood Fuses And Relays Page 1132 How To Read Ground Points Page 1697 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. System Diagnosis Air/Fuel Mixture: Testing and Inspection INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected HINT: All vacuum hoses for EGR systems, etc. should be properly connected. f. SFI system wiring connectors fully plugged. g. Ignition timing check correctly h. Transmission in neutral position i. Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft.) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When doing the 2 mode (idle and 2,500 rpm) test, these measurement order prescribed by the applicable local regulations. 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot according to the table. Page 1409 Wheel Bearing: Service Precautions Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Denso Made Cruise Control Module: Description and Operation Denso Made CIRCUIT DESCRIPTION The ECU power source supplies power to the actuator and sensors, etc., when terminal GND and the cruise control ECU case are grounded. Page 1703 How To Read Ground Points Page 20 Brake Fluid Solenoid Valve Relay: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Denso Made System Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation Denso Made System CIRCUIT DESCRIPTION The signal from the vehicle speed sensor circuit is sent to cruise control ECU as vehicle speed signal. For each rotation of the shaft, the vehicle speed sensor sends a signal through the combination meter to the cruise control ECU. The ECU calculates the vehicle speed from this pulse frequency. Page 1671 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. DISCONNECT AIR PIPE Remove the 2 bolts and disconnect the air pipe from the fan shroud. 4. DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR 5. REMOVE OIL DIPSTICK GUIDE a. Remove the bolt, dipstick guide and engine wire bracket. b. Remove the O-ring from the dipstick guide. HINT: At the time of installation, please refer to the following items. Use a new O-ring. Page 3004 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Denso Made System Brake Switch (Cruise Control): Testing and Inspection Denso Made System CIRCUIT DESCRIPTION When the brake pedal is on depressed, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP- of the ECU, and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. If the harness connected to terminal STP- has an open circuit, terminal STP- will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch is cut mechanically by the stop light switch, turning the cruise control off. (See DTC-12, Magnetic clutch Circuit) WIRING DIAGRAM Step 1 Page 2027 Page 2627 Page 2536 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Page 3354 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 985 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2188 a. Check that air flows from ports E to P, and does not flow from ports E to F. b. Apply battery positive voltage across the terminals. c. Check that air flows from ports E to F, and does not flow from ports E to R If operation is not as specified, replace the VSV. 5. REINSTALL VSV Page 522 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 3379 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Service and Repair Valve Seat: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Capacity Specifications Fluid - Differential: Capacity Specifications Front Differential Differential Oil: With Automatic Disconnecting Differential (A.D.D.) ................................................................................................................................. 1.15L (1.22 Qt) Less A.D.D. ......................................................................................................................................... ........................................................... 1.10L (1.16 Qt) Rear Differential Differential Oil: 4WD Extra Long Model ............................................................................................... ................................................................................. 2.45L (2.58 Qt) With Locking Differential: Short Model ................................................................................................................................................... ............................................... 2.65L (2.80 Qt) Extra Long Model ....................................................... .................................................................................................................................. 2.95L (3.18 Qt) Less Locking Differential ..................................................................................................................... ......................................................... 2.55L (2.69 Qt) Page 2348 Page 2431 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3306 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 417 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Testing and Inspection Turn Signal Switch: Testing and Inspection Turn Signal INSPECT TURN SIGNAL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 3099 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Locations EFI Main Relay: Locations Underhood Fuses And Relays Page 1031 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Diagram Information and Instructions Electronic Brake Control Module: Diagram Information and Instructions Page 551 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2727 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3350 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 58 After replacing the cruise control ECU, perform the cable adjustment procedure as necessary. 1. Confirm cable free play: A. Eliminate slack of inner cable by pushing the inner cable toward the actuator until it stops. While the cable is held, mark the position of the cable by using tape. B. Pull the inner cable toward the throttle cam and measure the clearance between the mark and the outer cable tip. 2. Adjust the cable free play: A. Loosen lock nut of throttle cam side and adjust the clearance to 1 or 2 mm. B. Tighten lock nut of actuator side. Torque: 12 N-m/8 ft-lbs C. Confirm clearance of 1 to 2 mm. Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake 0.15-0.25 mm (0.006-0.010 in) Exhaust 0.25-0.35 mm (0.010-0.014 mm) Diagram Information and Instructions Mass Air Flow Meter: Diagram Information and Instructions Page 960 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1163 System Outline The 4WD ECU operates the 2-4 select motor in accordance with the conditions of the 2-4 select SW, the detection SW (Transfer 4WD position) and the detection SW (Transfer L4 position). It also controls the range over which shifting from H2 to H4 is possible based ON the vehicle speed sensor. If the 2-4 select SW is pushed in while shifting is prohibited, it causes the 4WD indicator light to flash and sounds a warning buzzer to inform the driver. The warning buzzer is built into the ECU. The operation of the ECU is as follows. 2-4 SELECT SYSTEM The 2-4 select system selects between 2WD and 4WD by means of a 2-4 select SW located in the transfer shift lever knob which provides good operability. This system uses an ECU which drives the 2-4 select motor in accordance with signals from various sensors and accomplishes shifting between 2WD and 4WD. Shifting between H4 to L4 is accomplished by operating the transfer shift lever as before. This system also permits shifting between H2 and H4 without first shifting to H4. All models equipped with 2-4 select system are also equipped with the add, explained later. 1. Shifting from H4 to H2 When the 2-4 select SW is turned OFF. a signal is input to the 2-4 select motor from the 4WD ECU, activating the 2-4 select motor so that the transfer changes to 2WD (H2 position). At this time, the detection SW (Transfer 4WD position) and ADD indicator SW are OFF, so the 4WD indicator light goes OFF. 2. Shifting from H2 to H4 (During normal driving) When the 2-4 select SW is turned ON, a signal is input to the 2-4 select motor from the 4WD ECU, activating the 2-4 select motor so that the transfer changes to 4WD (H4 position) 3. Shifting from H2 to H4 (High speed driving) The vehicle speed within below approx. 100 kph, 62 mph. activating the 2-4 select motor so that the transfer changes to 4WD (H4 position) The 4WD ECU stops the signal to the 2-4 select motor with the signal from the vehicle speed sensor. At the same time, it causes the 4WD indicator light to light up and the warning buzzer inside the 4WD ECU to sound. 4. Shifting to L4 When the transfer shift lever is moved to L4 position, the transfer changes to LO position. This turns the detection SW (Transfer L4 position) ON so regardless of whether the 2-4 select SW is ON or OFF, a signal is input to the 2-4 select motor from the 4WD ECU, activating the 2-4 select motor so that the transfer changes to 4WD (L4 position) in LO condition. Connector Joining Wire Harness and Wire Harness Page 3122 Fuel Pressure Release: Service and Repair GENERAL PRECAUTIONS 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal removed from The battery. Therefore, if necessary, read the diagnostic trouble code(s) before removing the negative (-) terminal cable from the battery. 2. Do not smoke or work near an open flame when working on the fuel system. FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH PRESSURE FUEL LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: - Put a container under the connection. - Slowly loosen the connection. - Disconnect the connection. - Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use a new gasket. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare and tighten the flare nut by hand. - Using SST, tighten the flare nut to the specified torque. SST 09631-22020 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Page 1819 Exhaust Manifold: Testing and Inspection For information regarding the testing and inspection of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair; Disassembly and Reassembly. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Page 3040 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 72 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1947 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2920 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 2601 Knock Sensor: Testing and Inspection 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR a. Disconnect the knock sensor connector. b. Using SST remove the knock sensor. SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Using SST, install the knock sensor. SST 09816-30010 Torque: 44 Nm (450 kg.cm, 33 ft.lb) b. Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 Nm (200 kg.cm, 14 ft.lb) 7. REINSTALL STARTER Page 2926 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 3385 Page 2647 CHART 23 Page 3217 How To Read Ground Points Page 921 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2996 Page 767 CHART 30 Page 123 Headlamp Dimmer Relay: Testing and Inspection INSPECT HEADLIGHT DIMMER RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 3322 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Specifications Compression Check: Specifications Compression Pressure 1230 kPa (178 psi) or more Minimum Pressure 880 kPa (127 psi) Difference Between Each Cylinder 98 kPa (14 psi) or less Denso Made Cruise Control Switch: Description and Operation Denso Made CIRCUIT DESCRIPTION This circuit carries the SET/COAST, RESUME/ACCEL and CANCEL signals (each voltage) to the ECU. Page 830 Step 2 Step 3 Page 1372 Loosen/Tighten Bleeder Plug 3. CONNECT VINYL TUBE TO BRAKE CALIPER OR WHEEL CYLINDER BLEEDER PLUG Insert the other end of the tube in a half-full container of brake fluid. HINT: Begin air bleeding from the wheel cylinder with the longest hydraulic line. 4. BLEED BRAKE LINE a. Slowly depress the brake pedal several times. b. While an assistant depresses the pedal, loosen the bleeder plug until fluid starts to run out. Then tighten the bleeder plug. c. Repeat this procedure until there are no more air bubbles in the fluid. Torque: (bleeder plug) 11 Nm (110 kgf-cm, 8 ft. lbs.) 5. REPEAT PROCEDURE FOR EACH WHEEL. LOAD SENSING PROPORTIONING AND BY-PASS VALVE (LSP & BV) ON-VEHICLE INSPECTION HINT: Pre runner is described below. RZN191L-TRPDKAB, RZN196LCRPDKAB, VZN195L-CRPDKAB 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): 2. INSTALL LSP & BV GAUGE (SST) AND BLEED AIR SST 09709-29018 Page 795 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 846 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2114 How To Read Ground Points Page 2548 Step 6 Step 7 INSPECTION PROCEDURE Page 1862 Engine Control Module: Connector Views Part 1 Of 2 Page 2725 Mass Air Flow Meter: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 865 How To Read Ground Points Page 1357 j. With the engine idling and valve fully opened, turn the steering wheel to full lock. Minimum fluid pressure: 8,336 kPa (85 kgf/cm2,1,209 psi) NOTICE: ^ Do not maintain lock position for more than 10 seconds. ^ Do not let the fluid temperature become too high. k. Disconnect the SST l. Connect the pressure feed tube. m. 5VZ-FE Engine: Install the air cleaner and 3 bolts. n. Bleed the power steering system. Page 2374 INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 1643 Ignition Cable: Testing and Inspection INSPECT HIGH-TENSION CORDS a. Remove the air cleaner cap and MAF meter assembly. b. Remove the intake air connector. c. Disconnect the high-tension cords from the spark plugs. NOTE: Pulling on or bending the cords may damage the conductor inside. d. Disconnect the high-tension cords from the ignition coils. 1. Using a screwdriver, lift up the lock claw and disconnect the holder from the ignition coils. 2. Disconnect the high-tension cord at the grommet. NOTE: Pulling on or bending the cords may damage the conductor inside. - Do not wipe any of the oil from the grommet after the high- tension cord is disconnected. e. Using an ohmmeter, measure the resistance. Maximum resistance: 25 kohms per cord Page 3209 Fuel Supply Line: Service and Repair 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnostic trouble code(s) before removing the negative (-) terminal cable from the battery. 2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL SYSTEM 3. KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS 4. FUEL SYSTEM a. When disconnecting the high pressure fuel line, a large amount of gasoline will spill out, so observe these procedures: 1. Put a container under the connection. 2. Slowly loosen the connection. 3. Disconnect the connection. 4. Plug the connection with a rubber plug. b. When connecting the flare nut or union bolt on the high pressure pipe union, observe these procedures: 1. (Union Bolt Type) Always use a new gasket. 2. (Union Bolt Type) Tighten the union bolt by hand. 3. (Union Bolt Type) Tighten the union bolt to the specified torque. Torque: 29 Nm (300 kg.cm, 22 ft.lb) 4. (Flare Nut Type) Apply a light coat of engine oil to the flare and tighten the flare nut by hand. 5. (Flare Nut Type) Using SST, tighten the flare nut to the specified torque. SST 09631-22020 Torque: 30 Nm (310 kg.cm, 22 ft.lb) Page 1138 Transmission Temperature Sensor/Switch: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 474 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1266 - Remove the adjusting shim with a small screwdriver and magnetic finger. b. Determine the replacement adjusting shim size by these Formula or Charts: - Using a micrometer, measure the thickness of the removed shim. - Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T...Thickness of removed shim A...Measured valve clearance N...Thickness of new shim Intake: N = T + (A - 0.20 mm (0.008 inch)) Exhaust: N = T + (A - 0.30 mm (0.012 inch)) Page 2503 Crankshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. Torque: Bolt A: 74.5 Nm (760 kg.cm, 55 ft.lb) Bolt B: 18 Nm (180 kg.cm, 13 ft.lb) 4. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5. REMOVE CRANKSHAFT POSITION SENSOR a. Remove the 2 bolts and crankshaft position sensor. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) b. Remove the O-ring. HINT: At the time of installation, please refer to the following items. - Always use a new O-ring when installing the crankshaft position sensor. - Apply a light coat of engine oil on the O-ring. INSTALLATION Installation is in the reverse order of removal. Page 3261 Step 1 Step 2 Page 1706 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2983 How To Read Ground Points Page 2618 Page 2043 O2S Application Table O2S Failure Threshold Charts Page 283 Page 2308 a. Check heated oxygen sensor operation. b. Check and correct the cause if necessary. Page 242 Underdash Fuses And Relays Details Page 962 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 27 Page 3312 INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 447 How To Read Ground Points Page 2456 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 1995 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 815 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3138 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2868 CHART 11 Page 2691 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2200 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1761 Required SSTs Radiator Cap Identification Procedure 1. Use the illustration below to identify the vehicle's radiator cap type and kPa rating. 2. Proceed to the required inspection procedure for the radiator cap and kPa rating. Radiator Cap Inspection Procedure Type: N-cap, 88 kPa 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A," "B," and "C" are not deformed, cracked, or swollen. 3. Check that points "C" and "D" are not stuck together. 4. Apply engine coolant to points "B" and "C" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) Page 755 Page 2379 How To Read Ground Points Page 964 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Locations EFI Main Relay: Locations Underhood Fuses And Relays Page 2934 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3123 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Page 476 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1887 Underdash Fuses And Relays Details Page 484 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1538 Engine Oil: Service and Repair REPLACEMENT CAUTION: Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. - Care should be taken, therefore, when changing engine, oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The skin should be thoroughly washed with soap and water, or use water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. - In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. 1. DRAIN ENGINE OIL a. Remove the oil filler cap. b. Remove the oil drain plug, and drain the oil into a container. 2. REPLACE OIL FILTER a. Using Special Service Tool (SST), remove the oil filter. (SST) 09228-07501 b. Check and clean the oil filter installation surface. c. Apply clean engine oil to the gasket of a new oil filter. d. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. e. Using SST, tighten it an additional 3/4 turn. SST 09228-07501 3. REFILL WITH ENGINE OIL a. Clean and install the oil drain plug with a new gasket. Torque: 37 Nm (375 kgf.cm, 27 ft. lbs.) b. Fill with fresh engine oil. Oil capacity 2WD: Dry fill: 6.2 liters (6.6 US qts., 5.5 Imp. qts.) Drain and refill w/ Oil filter change: 5.5 liters (5.8 US qts., 4.8 Imp. qts.) w/o Oil filter change: 4.8 liters (5.0 US qts., 4.2 Imp. qts.) 4WD: Dry fill: 5.8 liters (6.1 US qts., 5.1 Imp. qts.) Drain and refill Page 368 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1988 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 252 Underdash Fuses And Relays Details Page 763 CHART 27 Page 2975 Vehicle Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 2809 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2317 Fuel Pressure Release: Service and Repair GENERAL PRECAUTIONS 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal removed from The battery. Therefore, if necessary, read the diagnostic trouble code(s) before removing the negative (-) terminal cable from the battery. 2. Do not smoke or work near an open flame when working on the fuel system. FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH PRESSURE FUEL LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: - Put a container under the connection. - Slowly loosen the connection. - Disconnect the connection. - Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use a new gasket. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare and tighten the flare nut by hand. - Using SST, tighten the flare nut to the specified torque. SST 09631-22020 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Page 1041 Page 1681 Coolant: Testing and Inspection INSPECTION 1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The coolant level should be between the "L" and "F" lines. If low, check for leaks and add coolant up to the "F" line. 2. CHECK ENGINE COOLANT QUALITY a. Remove the radiator cap. WARNING: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. b. There should not be any excessive deposits of rust or scales around the radiator cap or radiator filler hole, and the coolant should be free from oil. If excessively dirty, replace the coolant. c. Reinstall the radiator cap. Page 2876 CHART 21 Page 1268 - Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch). c. Install a new adjusting shim. - Place a new adjusting shim on the valve lifter. Page 2136 Step 4 INSPECTION PROCEDURE Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Page 167 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 821 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2642 CHART 20 Page 2073 Page 2009 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 649 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2515 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 165 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Page 2066 CHART 26 Page 2669 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 3032 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2855 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 792 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Denso Made Transmission Position Switch/Sensor: Testing and Inspection Denso Made CIRCUIT DESCRIPTION When the shift position is put in positions except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM Step 1 Page 2410 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 391 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1144 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Diagram Information and Instructions Brake Fluid Solenoid Valve Relay: Diagram Information and Instructions Page 1607 HINT: If necessary, install the gear with Special Service Tool (SST). (SST) 09636-20010 8. INSTALL NO.1 TIMING CHAIN AND CAMSHAFT TIMING GEAR a. Align the timing mark between the mark link of the No.1 timing chain, and install the No.1 timing chain to the timing gear. b. Align the timing mark of the crankshaft timing gear with the mark link of the No.1 timing chain and install the No.1 timing chain. c. Tie the No.1 timing chain with a cord as shown in the illustration, and make sure it doesn't come loose. 9. INSTALL TIMING CHAIN COVER a. Install 3 new gaskets to the cylinder block and water bypass pipe. b. Install the timing chain cover with the 9 bolts and 2 nuts. Torque: Bolt: 12 mm head A: 20 Nm (200 kgf.cm,14 ft. lbs.) 12 mm head B: 24.5 Nm (250 kgf.cm,18 ft. lbs.) 14 mm head: 44 Nm (440 kgf.cm, 32 ft. lbs.) Nut: 20 Nm (200 kgf.cm, 14 ft. lbs.) Page 1146 Transmission Temperature Sensor/Switch: Description and Operation CIRCUIT DESCRIPTION The ATF temperature sensor converts fluid temperature into a resistance value which is input into the ECM. Page 207 Page 794 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 422 Clutch Switch: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1264 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE PCV HOSES 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. DISCONNECT ENGINE WIRE a. Disconnect these connectors: - w/ A/C: A/C compressor connector - Oil pressure sensor connector - Engine coolant temperature sender gauge connector - Ignition Coil connector b. Disconnect the 4 engine wire clamps and engine wire. 5. REMOVE CYLINDER HEAD COVER Remove the 10 bolts, seal washers, cylinder head cover and gasket. 6. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley clockwise and align its groove with the "0" mark on the timing chain cover. b. Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. 7. INSPECT VALVE CLEARANCE Page 811 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3041 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 163 Engine Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3193 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 2870 CHART 14 Page 878 Page 2204 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2014 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1910 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 939 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 759 CHART 25 Page 291 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 290 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 3081 Exhaust Gas Recirculation Gas Temperature Sensor: Testing and Inspection COMPONENTS INSPECTION 1. REMOVE EGR VALVE 2. REMOVE EGR GAS TEMPERATURE SENSOR 3. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 64 - 97 kohms at 50 °C (122 °F) 11 - 16 kohms at 100 °C (212 °F) 2 - 4 kohms at 150 °C (302 °F) If the resistance is not as specified, replace the sensor. 4. REINSTALL EGR GAS TEMPERATURE SENSOR 5. REINSTALL EGR VALVE Page 1979 Page 1762 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01 (09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: N-cap, 108 kPa Page 69 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 169 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 2227 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1397 Underdash Fuses And Relays Details Page 1902 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolt 260 Nm (193 ft.lb) No.2 & No.3 Crankshaft Pulley Bolts (4) 25 Nm (18 ft.lb) Page 2133 Step 4 INSPECTION PROCEDURE Page 2594 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 483 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1859 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3221 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 710 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 756 CHART 23 Page 3236 Part 3 Of 4 Page 965 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2974 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 1527 Assenmacher Specialty Tools 1-800-525-2943 Testing and Inspection Oil Pressure Sender: Testing and Inspection INSPECT LOW OIL PRESSURE SWITCH a. Disconnect the connector from the switch. b. Check that continuity exists between terminal and ground with the engine stopped. c. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 49 kPa (0.5 kg/Sq.cm, 7.1 psi). If operation is not as specified, replace the switch. Page 2492 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2916 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2549 Engine Control Module: Service and Repair COMPONENTS REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE LOWER FINISH NO.2 PANEL 3. REMOVE ECM a. Disconnect the 4 ECM connectors. b. Remove the 2 bolts and ECM. INSTALLATION Installation is in the reverse order of removal. Page 684 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1110 Transmission Position Switch/Sensor: Electrical Diagrams Page 711 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2477 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 3265 b. Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 c. After engine speed is kept at approx. 1,000 - 1500 rpm for 5 seconds, check that it returns to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. d. Remove the SST. SST 09843-18020 Page 2939 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1867 Part 2 Of 2 Page 2229 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 1905 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 482 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3372 How To Read Ground Points Page 2565 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2561 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 160 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 530 Fuel Gauge Sender: Electrical Diagrams Part 1 Of 4 Locations Overdrive Relay: Locations Underhood Fuses And Relays Page 732 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Service and Repair Oil Filter: Service and Repair For information regarding the service and repair of this component, please refer to Oil; Service and Repair. Page 2693 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Cooling System - Leak at Radiator Overflow Hose Radiator: Customer Interest Cooling System - Leak at Radiator Overflow Hose ENGINE EG012-99 November 5, 1999 Title: RADIATOR LEAK FROM OVERFLOW PIPE Models: '98 - '99 Tacoma Introduction Due to a casting mismatch, some 1998 - 1999 Tacomas may experience a leak from the coolant overflow pipe hose where it connects to the radiator upper tank. Affected Vehicles ^ 1998 - 1999 model year Tacoma produced between the VINs specified as shown. Parts Information Repair Procedure 1. Remove the overflow hose from the overflow pipe. 2. Using 240 grit sandpaper, smooth the outer surface of the overflow pipe on the upper radiator tank as shown. 3. Repeat using 400 grit sandpaper. 4. Reinstall hose utilizing the field fix Clip. NOTE: Do not use a knife for this procedure and do not sand in a horizontal direction. Warranty Information Page 2901 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2742 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2056 CHART 20 Page 532 Part 3 Of 4 Diagram Information and Instructions Mass Air Flow Meter: Diagram Information and Instructions Specifications Compression Check: Specifications Compression Pressure 1230 kPa (178 psi) or more Minimum Pressure 880 kPa (127 psi) Difference Between Each Cylinder 98 kPa (14 psi) or less Page 2556 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2015 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1467 Crankshaft Main Bearing: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 2786 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 753 CHART 21 Page 2902 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1181 Four Wheel Drive Selector Switch: Testing and Inspection INSPECTION 1. INSPECT 2-4 SELECTOR SWITCH CONTINUITY If continuity is not as specified, replace the shift lever knob. 2. INSPECT ACTUATOR RESISTANCE a. Using an ohmmeter, measure the resistance between terminals 2 and 3. Standard resistance: 0.3 - 100 Ohms b. Using an ohmmeter, measure the resistance between terminals 2 or 3 and body ground. Standard resistance: More than 0.5 M Ohms If resistance value is not as specified, replace the actuator assembly. Page 1499 Fuel Pressure Release: Service and Repair GENERAL PRECAUTIONS 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal removed from The battery. Therefore, if necessary, read the diagnostic trouble code(s) before removing the negative (-) terminal cable from the battery. 2. Do not smoke or work near an open flame when working on the fuel system. FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH PRESSURE FUEL LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: - Put a container under the connection. - Slowly loosen the connection. - Disconnect the connection. - Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use a new gasket. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare and tighten the flare nut by hand. - Using SST, tighten the flare nut to the specified torque. SST 09631-22020 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Page 1119 Step 4 INSPECTION PROCEDURE Page 2145 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2890 CHART 30 Page 3263 Step 6 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air-fuel ratio lean or rich, etc. at the time of the malfunction. Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Page 1415 Axle Nut: Specifications Backing Plate Mounting Nuts (4) 68 Nm (50 ft.lb) Page 766 CHART 29 Page 692 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 503 Evaporator Temperature Sensor / Switch: Testing and Inspection On Vehicle Inspections 1. REMOVE GLOVE COMPARTMENT DOOR 2. INSPECT THERMISTOR RESISTANCE a. Disconnect the connector b. Measure resistance between terminals 2 and 5. Standard resistance: 1,500 Ohms at 25 °C (77 °F) If resistance is not as specified, proceed next inspection. System Diagnosis Air/Fuel Mixture: Testing and Inspection INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected HINT: All vacuum hoses for EGR systems, etc. should be properly connected. f. SFI system wiring connectors fully plugged. g. Ignition timing check correctly h. Transmission in neutral position i. Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft.) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When doing the 2 mode (idle and 2,500 rpm) test, these measurement order prescribed by the applicable local regulations. 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot according to the table. Page 869 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 398 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3152 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch LOCK. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Page 2211 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. Page 2383 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 208 Page 664 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2118 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 128 Locations Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Page 3154 INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 23 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Exhaust System - Manifold Heat Shield Rattle Noise Heat Shield: Customer Interest Exhaust System - Manifold Heat Shield Rattle Noise Engine EG004-00 June 2, 2000 Title: EXHAUST MANIFOLD HEAT SHIELD RATTLE NOISE Models: '95 - '00 Tacoma Introduction Some Tacoma vehicles may experience a rattle noise caused by the exhaust manifold heat shield. Two wire mesh grommets and a reinforcement patch on the underside have been added to reduce the possibility of the exhaust manifold heat shield rattle noise. Applicable Vehicles ^ 1995 - 2000 model year Tacoma vehicles (except CA Spec.) equipped with 2RZ-FE or 3RZ-FE engines produced before the VINs listed. Production Change Information Parts Information Repair Procedure 1. Inspect the Exhaust Manifold Heat Shield for cracking around the 2 bolts and 2 studs. 2. If cracking is found, replace the Exhaust Manifold Heat Shield, Bolts, Washers, Studs, and Nuts in specified quantities. 3. Insert 2 bolts. (P/N 90110-06894) 4. Reuse studs/nuts in the specified areas. Warranty Information Page 1945 How To Read Ground Points Page 1871 Engine Control Module: Service and Repair COMPONENTS REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE LOWER FINISH NO.2 PANEL 3. REMOVE ECM a. Disconnect the 4 ECM connectors. b. Remove the 2 bolts and ECM. INSTALLATION Installation is in the reverse order of removal. Page 1788 Page 762 Page 2274 Crankshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. Torque: Bolt A: 74.5 Nm (760 kg.cm, 55 ft.lb) Bolt B: 18 Nm (180 kg.cm, 13 ft.lb) 4. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5. REMOVE CRANKSHAFT POSITION SENSOR a. Remove the 2 bolts and crankshaft position sensor. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) b. Remove the O-ring. HINT: At the time of installation, please refer to the following items. - Always use a new O-ring when installing the crankshaft position sensor. - Apply a light coat of engine oil on the O-ring. INSTALLATION Installation is in the reverse order of removal. Page 752 Page 2029 A/F and 02 Sensor Identification Page 2386 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Locations Page 70 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2589 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1028 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 934 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 486 Vehicle Speed Sensor/Transducer - Cruise Control: Electrical Diagrams Page 2829 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. A/T - Fluid Interchangeability Fluid - A/T: Technical Service Bulletins A/T - Fluid Interchangeability TRANSMISSION & CLUTCH TC003-99 Title: AUTOMATIC TRANSMISSION FLUIDS Models: All Models May 21, 1999 REVISION NOTICE: The information contained in this TSB updates TC003-98 dated June 19, 1998. Introduction Automatic Transmission Fluid Type T-IV now replaces Type T-II fluid. Use Type T-IV for all applications that specify ATF Type T-II. Please refer to the following table for the interchangeability between each ATF. Affected Vehicles ^ All vehicles produced after 1993 with Automatic Transmissions specified to use ATF Type T, T-II and T-IV. NOTICE: With the exception of mixing ATF Type T with Type T-IV fluids, different types of fluids must not be mixed. Parts Information SIZE NEW PART NUMBER PART NAME 4 Liter 08886-01705 ATF Type T-IV Warranty Information Page 3208 Fuel Line Inspection a. Check the fuel lines for cracks or leakage, and all connections for deformation. b. Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. c. Check the fuel tank for deformation, cracks, fuel leakage or tank band looseness. d. Check the filler neck for damage or fuel leakage. e. Hose and pipe connections are as shown in the illustration. If a problem is found, repair or replace the parts as necessary. Page 2404 Brake Signal: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2832 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3231 Part 2 Of 4 Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Page 3249 Idle Air Control Valve: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1227 a. Check heated oxygen sensor operation. b. Check and correct the cause if necessary. Page 1856 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3358 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 828 Step 4 INSPECTION PROCEDURE Page 3336 3. INSPECT THROTTLE OPENER a. Allow the engine to warm up to normal operating temperature. b. Check the idle speed. Idle speed: 650 - 750 rpm c. Disconnect the vacuum hose from the throttle opener, and plug the hose end. d. Check the throttle opener setting speed. Throttle opener setting speed: 1,200 - 1,500 rpm If the throttle opener setting is not as specified, replace the throttle body. e. Stop the engine. f. Reconnect the vacuum hose to the throttle opener. g. Start the engine, and check that the idle speed returns to the correct speed. h. Disconnect TOYOTA hand-held tester or OBDII scan tool. Page 922 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2674 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 1107 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 144 Underdash Fuses And Relays Details Page 1800 Thermostat: Service and Repair REMOVAL HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. 1. DRAIN ENGINE COOLANT 2. DISCONNECT WATER INLET WITH LOWER RADIATOR HOSE, AND REMOVE THERMOSTAT a. Remove the 2 nuts holding the water inlet to the inlet housing, and disconnect the water inlet from the inlet housing. b. Remove the thermostat. c. Remove the gasket from the thermostat. INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. a. Immerse the thermostat in water and gradually heat the water. Page 2459 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the engine wire protector from the 3 brackets. b. Disconnect the ECT sensor connector. c. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Page 545 Underhood Fuses And Relays Service Hints B 6 BUCKLE SW 1-2 : Open with Driver's Seat Belt in use D15 DOOR COURTESY SW LH 1-GROUND : Closed with LH Door open Page 2798 Crankshaft Position Sensor: Description and Operation Crankshaft position sensor (NE signal) consists of a signal plate and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle and the engine speed by the NE signals. Page 525 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 430 Page 2769 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2011 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1042 Overdrive Switch: Description and Operation O/D Main Switch & O/D Off Indicator Light The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising overdrive may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels overdrive shifting until these signals are discontinued. Specifications Piston Ring: Specifications Piston Ring Groove Clearance No.1 0.020-0.070 mm No.2 0.030-0.070 mm Piston Ring Eng Gap No.1 0.300-0.400 mm No.2 0.400-0.500 mm Locations Blower Motor Relay: Locations Underhood Fuses And Relays Page 1708 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 883 a. Check that air flows from ports E to P, and does not flow from ports E to F. b. Apply battery positive voltage across the terminals. c. Check that air flows from ports E to F, and does not flow from ports E to R If operation is not as specified, replace the VSV. 5. REINSTALL VSV Page 2624 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Page 2596 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 677 Crankshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. Torque: Bolt A: 74.5 Nm (760 kg.cm, 55 ft.lb) Bolt B: 18 Nm (180 kg.cm, 13 ft.lb) 4. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5. REMOVE CRANKSHAFT POSITION SENSOR a. Remove the 2 bolts and crankshaft position sensor. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) b. Remove the O-ring. HINT: At the time of installation, please refer to the following items. - Always use a new O-ring when installing the crankshaft position sensor. - Apply a light coat of engine oil on the O-ring. INSTALLATION Installation is in the reverse order of removal. Specifications Firing Order: Specifications Firing order: 1-3-4-2 Page 768 Page 2771 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2048 CHART 8 CHART 9 Page 300 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2250 Page 890 How To Read Ground Points Page 1631 Fuel Pressure Release: Service and Repair GENERAL PRECAUTIONS 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal removed from The battery. Therefore, if necessary, read the diagnostic trouble code(s) before removing the negative (-) terminal cable from the battery. 2. Do not smoke or work near an open flame when working on the fuel system. FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH PRESSURE FUEL LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: - Put a container under the connection. - Slowly loosen the connection. - Disconnect the connection. - Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use a new gasket. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare and tighten the flare nut by hand. - Using SST, tighten the flare nut to the specified torque. SST 09631-22020 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Page 359 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 2699 Engine Control Module: Description and Operation DESCRIPTION The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to accomplish this control, the ECM relies on the input from a variety of engine operation sensors. The ECM compares input signals with those stored in memory to determine what steps should be taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM outputs the necessary signals to the fuel system, ignition system, emission control systems, etc.. Battery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is OFF for use by the DTC memory and air-fuel ratio adaptive control value memory, etc. Page 2703 Engine Control Module: Testing and Inspection Related Diagnostic Procedures CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Step 1 Page 3301 Mass Air Flow Meter: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1591 Page 91 Step 2 Step 3 INSPECTION PROCEDURE Page 1118 Step 2 Step 3 Denso Made Transmission Position Switch/Sensor: Testing and Inspection Denso Made CIRCUIT DESCRIPTION When the shift position is put in positions except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM Step 1 Page 2745 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 518 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 3373 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 3131 a. Check heated oxygen sensor operation. b. Check and correct the cause if necessary. Page 2159 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 1. DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. Page 735 Page 3022 Step 2 Step 3 Page 1374 (c) Torque the nuts. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) (d) Adjust the length of the No.1 shackle again. If it cannot be adjusted, inspect the valve housing. 5. IF NECESSARY, CHECK VALVE BODY (a) Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the position will move down about 0.8 mm (0.03 in.). Even at this time, the piston should not make contact with or move the load sensing spring. (b) In this position, check the rear brake pressure. if the measured value is not within the standard, replace the valve body. Page 2659 Page 1915 Mass Air Flow Meter: Description and Operation The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Page 646 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1166 Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 1973 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 714 Page 161 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 840 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2909 Oxygen Sensor: Testing and Inspection INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS a. Disconnect the heated oxygen sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: Bank 1 Sensor 1: 11 - 16 ohm at 20 °C (68 °F) Bank 1 Sensor 2: 11 - 16 ohm at 20 °C (68 °F) If resistance is not as specified, replace the heated oxygen sensor. c. Reconnect the heated oxygen sensor connector. Page 1516 VALVE SHIMS Page 1889 EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION a. Apply battery positive voltage across terminals 86 and 85. b. Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Page 1154 Junction Block and Wire Harness Connector Page 504 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. REMOVE EVAPORATOR 2. REMOVE THERMISTOR a. Disconnect the connector clamp. b. Pull out the thermistor from evaporator. INSTALLATION Installation is in the reverse order of removal. Page 3224 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1321 Fluid - A/T: Service and Repair 1. Operate vehicle, allow transmission fluid temperature to reach 158-176 °F. 2. Position vehicle on level surface, apply parking brake. 3. Allow engine to idle, depress brake pedal, then move shift lever through all positions. 4. Remove transaxle dipstick, wipe clean, then replace. 5. Remove again, then check fluid level in HOT range. NOTICE: Do not overfill. (a) Check the fluid condition. If the fluid smells burnt or is black, replace it. (b) Replace the ATF. (1) Remove the drain plug and drain the fluid. (2) Reinstall the drain plug securely. 7. On A340D units: Dry capacity is 6.9 US quarts. Drain and Refill: 2.4 Liters (2.5 US qts, 2.1 Imp. qts.) 8. On A340E units: Dry capacity is 7.6 US quarts. Drain and Refill: 1.6 Liters (1.7 US qts, 1.4 Imp. qts.) 9. On A340F units: Dry capacity 1996 9.3 US quarts. Dry capacity 1997-99 10.7 US quarts. Drain and Refill: 2.0 Liters (2.1 US qts, 1.8 Imp. qts.) 10. On A340H units, dry capacity for transaxle and transfer is 10.9 US quarts. Page 3376 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 642 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3380 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1517 Valve Spring Shim: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Valve Clearance; Service and Repair. Page 2942 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3244 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2976 Vehicle Speed Sensor: Testing and Inspection INSPECT VEHICLE SPEED SENSOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b. Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c. Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be performed 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. Page 337 How To Read Ground Points Page 3042 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 693 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 312 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 316 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 466 Step 2 Step 3 INSPECTION PROCEDURE Page 2253 Camshaft Position Sensor: Service and Repair COMPONENTS REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. b. Remove the bolts and camshaft position sensor. Torque: 5.4 Nm (55 kg.cm, 48 in.lb) INSTALLATION Installation is in the reverse order of removal. Page 1199 c. Push in the washer switch, and check that the voltage changes as shown in the table. If operation is not as specified, replace the wiper and washer switch. Page 3008 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1595 Diagram Information and Instructions Mass Air Flow Meter: Diagram Information and Instructions Page 2722 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 597 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1075 How To Read Ground Points Page 1767 5. When using the radiator cap tester, tilt it more than 30 degrees. 6. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Exhaust System - Sulfur Smell Fuel: Technical Service Bulletins Exhaust System - Sulfur Smell ENGINE EG003-03 February 24, 2003 Title: SULFUR ODOR FROM EXHAUST Models: All Models Introduction Some owners of Toyota vehicles may experience a sulfur-like or "rotten egg" odor from the exhaust system. Sulfur is a natural component of crude oil from which gasoline is refined and the amount of sulfur can be decreased through the refining process. The amount of sulfur in fuel sold in California is regulated, however gasoline sold in other states can have substantially higher sulfur content. Sulfur content also varies considerably between gasoline brands and locations. Applicable Vehicles ^ All Models. Repair Procedure A sulfur odor emitted from the vehicle's tailpipe does not necessarily indicate that there is an issue with the engine's running condition, but is most likely directly related to the fuel. ^ If the vehicle is exhibiting an excessive sulfur odor, the following checks should be performed: ^ If the MIL light is ON, check for DTCs and repair as necessary. If no trouble is found after performing the above check, recommend the customer try a different source of fuel. Replacement of oxygen sensors, air/fuel ratio sensors or catalytic converters will not reduce the odor and will therefore not be considered warrantable. Warranty Information Diagram Information and Instructions Transmission Mode Switch: Diagram Information and Instructions Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Page 2174 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2815 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Page 3298 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 408 Step 4 INSPECTION PROCEDURE Page 3182 a. Disconnect these connectors: 1. 4 injector connectors 2. Crankshaft position sensor connector 3. knock sensor connector 4. Camshaft position sensor b. Disconnect the DLC1 and wire clamp from the brackets. 3. REMOVE DELIVERY PIPE AND INJECTORS a. Disconnect the vacuum sensing hose from the fuel pressure regulator. b. Disconnect the fuel return hose from the fuel pressure regulator. c. Remove the union bolt and 2 gaskets, and disconnect the fuel inlet pipe from the delivery pipe. HINT: Put a suitable container or shop rag under the delivery pipe. - Slowly loosen the union bolt. d. Remove the 2 bolts and delivery pipe together with the 4 injectors. NOTE: Be careful not to drop the injectors when removing the delivery pipe. e. Remove the 4 insulators from the 4 spacers. f. Pull out the 4 injectors from the delivery pipe. g. Remove the O-ring and grommet from each injector. INSTALLATION 1. INSTALL INJECTORS TO DELIVERY PIPE a. Install a new grommet to the injector. b. Apply a light coat of gasoline to a new O-ring and install it to the injector. Page 2867 CHART 10 Page 139 Locations Page 536 Part 3 Of 4 Page 2640 CHART 16 CHART 17 Page 524 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Capacity Specifications Refrigerant: Capacity Specifications Refrigerant R134A 20.8 oz Page 2662 How To Read Ground Points Page 3202 Fuel Return Line: Testing and Inspection COMPONENTS CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. INSPECTION INSPECT FUEL TANK AND LINE Page 917 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 168 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3250 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2526 How To Read Ground Points Page 2053 CHART 15 Page 3166 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Refill With Filter ................................................................................................................................... ....................................................................... 5.8 Qt Without Filter ....................................................................................................................................... ........................................................................ 5.0 Qt NOTE: Listed capacities are approximate. Check fluid level after filling. Page 2406 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1081 Transmission Mode Switch: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1711 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1820 Exhaust Manifold: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair; Removal and Installation. Page 2848 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 401 Brake Switch (Cruise Control): Electrical Diagrams Locations Power Distribution Relay: Locations Underhood Fuses And Relays Injection Inspection Fuel Injector: Testing and Inspection Injection Inspection 1. INSPECT INJECTOR INJECTION CAUTION: Keep injector clean of sparks during the test. a. Remove the fuel inlet pipe from the fuel filter outlet. b. Connect SST (union and hose) to the fuel filter outlet with the 2 gaskets and union bolt. SST 09268-41047 (90405-09015) Torque: 29 Nm (300 kg.cm, 22 ft.lb) c. Remove the fuel pressure regulator from the delivery pipe. d. Install the O-ring to the fuel inlet of pressure regulator. e. Connect SST (hose) to the fuel inlet of the pressure regulator with SST (union) and the 2 bolts. SST 09268-41047 (09268-41091) f. Connect the fuel return hose to the fuel outlet of the pressure regulator. Page 129 Headlamp Relay: Testing and Inspection INSPECT HEADLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake 0.15-0.25 mm (0.006-0.010 in) Exhaust 0.25-0.35 mm (0.010-0.014 mm) Page 2764 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 272 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1103 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3033 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 311 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 824 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch go on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM. Terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in D position. When the shift position is except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. Page 2872 CHART 16 CHART 17 Page 1060 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2977 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 1. DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. Page 2369 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 449 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2258 How To Read Ground Points Page 2719 How To Read Ground Points Diagrams Specifications Camshaft Bearing: Specifications Camshaft Bearing Cap Bolts 15.5 Nm (12 ft.lb) Intake Sequence --Exhaust Sequence --- Diagram Information and Instructions Cruise Control Switch: Diagram Information and Instructions Page 843 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2756 Camshaft Position Sensor: Description and Operation The Camshaft position sensor (G signal) consists of a signal plate and pick up coil. The G signal plate has one tooth on its outer circumference and is mounted on the exhaust camshaft. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. Page 3340 4. REMOVE INTAKE AIR CONNECTOR a. Disconnect these air hoses and wire clamp: 1. Air hose for IAC 2. Vacuum sensing hose 3. Wire clamp for engine wire b. Remove the 2 bolts, hose clamp and intake air connector. 5. REMOVE PCV HOSE 6. REMOVE THROTTLE BODY a. Disconnect these hoses: 1. 3 vacuum hoses 2. EVAP hose 3. w/ PS: Air hose for PS idle-up b. Disconnect the throttle position sensor connector. c. Disconnect the IAC valve connector. d. Remove the 2 bolts, 2 nuts, and disconnect the throttle body from the air intake chamber. Torque: 20 Nm (200 kg.cm, 14 ft.lb) e. Remove the throttle body gasket. HINT: At the time of installation, please refer to the following items. Use a new gasket. f. Disconnect the water bypass hoses from the throttle body, and remove the throttle body. 7. REMOVE AIR HOSE FROM IAC VALVE INSTALLATION Page 2590 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2970 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1184 Part 1 Of 2 Part 2 Of 2 STANDARD VALUE OF ECU TERMINAL Page 1969 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2154 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1713 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 954 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 650 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1203 d. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2, check that the meter needle indicates battery positive voltage. If operation is not as specified, replace the wiper and washer switch. INSPECT REAR WIPER AND WASHER SWITCH CONTINUITY If continuity is not as specified, replace the switch. Testing and Inspection Catalytic Converter: Testing and Inspection 1. CHECK TWC FOR DENTS OR DAMAGE If any part of the protector is damaged or dented to the extent that it touches the three-way catalytic converter, repair or replace it. 2. CHECK EXHAUST PIPE CONNECTIONS FOR LOOSENESS OR DAMAGE 3. CHECK EXHAUST PIPE CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE 4. CHECK HEAT INSULATOR FOR DAMAGE 5. CHECK FOR ADEQUATE CLEARANCE BETWEEN TWC AND HEAT INSULATOR Service and Repair Lifter / Lash Adjuster: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 1682 Coolant: Service and Repair REPLACEMENT 1. REPLACE ENGINE COOLANT a. Remove the radiator cap. WARNING: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. b. Drain the coolant from the radiator and cylinder drain plugs. (Engine coolant drain plug at the right of cylinder block.) c. Close the drain plugs. Torque: Engine coolant drain plug: 24.5 Nm (250 kgf.cm, 18 ft. lbs.) 2. FILL ENGINE COOLANT a. Slowly fill the system with coolant. - Use a good brand of ethylene-glycol base coolant and mix it according to the manufacturer's directions. - Using coolant which includes more than 50 % ethylene-glycol (but not more than 70 %) is recommended. NOTICE: ^ Do not use an alcohol type coolant. ^ The coolant should be mixed with demineralized water or distilled water. Capacity (w/ Heater): 2WD: M/T: 8.0 liters (8.5 US qts., 7.0 Imp. qts.) A/T: 7.8 liters (8.2 US qts., 6.9 Imp. qts.) 4WD: M/T: 8.3 liters (8.8 US qts., 7.2 Imp. qts.) A/T: 8.2 liters (8.7 US qts., 7.2 Imp. qts.) b. Reinstall the radiator cap. c. Start the engine, and bleed the cooling system. d. If necessary, refill engine coolant into the radiator reservoir until it is "FULL" line. 3. CHECK ENGINE COOLANT FOR LEAKS Page 1780 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 14 How To Read Ground Points Page 621 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1190 HINT: The circuit breaker opens for some 4 - 40 seconds after the window stops going down, so that the check must be done before the circuit breaker operates. If operation is as specified, replace the master switch. Page 3255 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2199 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 1924 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1784 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2126 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2665 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 3101 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 3175 Fuel Injector: Capacity Specifications Injector Volume Injector Volume Resistance Per Injector 12-16 ohms Injection Volume 69-88 cm3 (4.2-5.4 cu in.) Per 15 seconds Difference Between Injectors 5 cm3 (0.3 cu in.) or less Leakage Rate Per Injector 1 drop or less per 3 Minutes Page 2049 CHART 10 Page 3012 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 605 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Intake Manifold Intake Manifold: Specifications Intake Manifold Fasteners 29 Nm (22 ft.lb) Page 2794 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1998 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3230 Fuel Gauge Sender: Electrical Diagrams Part 1 Of 4 Page 340 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 635 Camshaft Position Sensor: Service and Repair COMPONENTS REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. b. Remove the bolts and camshaft position sensor. Torque: 5.4 Nm (55 kg.cm, 48 in.lb) INSTALLATION Installation is in the reverse order of removal. Valve Cover Oil Baffle - Damage Prevention Valve Cover: Technical Service Bulletins Valve Cover Oil Baffle - Damage Prevention ENGINE EG007-02 Title: GENERAL MAINTENANCE TIP Models: All '93 - '03 Models March 22, 2002 Introduction To help prevent unnecessary complications during the oil fill process, no undue load should be placed on the oil baffle attached to the inside of the valve cover (see illustration). This baffle is designed to deflect oil and should not be used to support the weight of heavy oil fill devices. These devices can place stress on the baffle, and bend or break it during the oil fill process. Applicable Vehicles ^ All 1993 - 2003 model year Toyota vehicles. Oil Filling Procedure Please take measures to ensure that the baffle is not damaged during the oil fill process. If it does become damaged, repair it before any collateral damage occurs. Warranty Information Page 3262 Step 3 Step 4 Step 5 Page 1051 O/D OFF indicator light remains ON Page 1165 Ground Points Page 852 Vehicle Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 2675 Page 1875 Underdash Fuses And Relays Details Page 1670 Water Pump: Service and Repair Page 2825 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Page 2800 Crankshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. Torque: Bolt A: 74.5 Nm (760 kg.cm, 55 ft.lb) Bolt B: 18 Nm (180 kg.cm, 13 ft.lb) 4. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5. REMOVE CRANKSHAFT POSITION SENSOR a. Remove the 2 bolts and crankshaft position sensor. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) b. Remove the O-ring. HINT: At the time of installation, please refer to the following items. - Always use a new O-ring when installing the crankshaft position sensor. - Apply a light coat of engine oil on the O-ring. INSTALLATION Installation is in the reverse order of removal. Page 375 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2592 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 845 Vehicle Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 334 Page 2123 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2106 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 900 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1967 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2605 Underdash Fuses And Relays Details Page 2467 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1956 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Diagram Information and Instructions Acceleration/Deceleration Sensor: Diagram Information and Instructions Page 40 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 855 b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Torque: 5.4 Nm (55 kgf cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 2885 Page 1608 c. Install the 2 timing chain cover bolts. Torque: 18 Nm (185 kgf.cm,13 ft. lbs.) d. Install the 2 water bypass pipe nuts. Torque: 20 Nm (200 kgf.cm,14 ft. lbs.) e. Remove the cord from the chain. 10. INSTALL CRANKSHAFT PULLEY a. Align the pulley set key with the key groove of the pulley, and slide on the pulley. b. Using SST, install and torque the pulley bolt. SST 09213-54015, 09330-00021 Torque: 260 Nm (2,650 kgf.cm, 193 ft. lbs.) c. w/ A/C: Install the No.3 and No.2 crankshaft pulleys with the 4 bolts. Torque: 25 Nm (250 kgf.cm,18 ft. lbs.) 11. INSTALL OIL STRAINER Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 18 Nm (185 kgf.cm,13 ft. lbs.) 12. INSTALL OIL PAN a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the oil pan. - Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. - Thoroughly clean all components to remove all the loose material. - Using a non-residue solvent, clean both sealing surfaces. NOTICE: Do not use a solvent which will affect the painted surfaces. Page 2105 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 232 Locations Page 1539 w/ Oil filter change: 5.4 liters (5.7 U S qts., 4.8 Imp. qts.) w/o Oil filter change: 4.7 liters (5.0 US qts., 4.1 Imp. qts.) Reinstall the oil filler cap. 4. START ENGINE AND CHECK FOR LEAKS 5. RECHECK ENGINE OIL LEVEL Diagram Information and Instructions Vapor Pressure Sensor: Diagram Information and Instructions Page 1085 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Diagram Information and Instructions Throttle Position Sensor/Switch: Diagram Information and Instructions Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Page 669 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1171 Page 3024 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES. 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH. Torque: Nut: 6.9 Nm (70 kgf cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR CONNECT 2 OIL COOLER PIPES Page 715 Knock Sensor: Description and Operation The knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 2065 Page 1275 Assenmacher Specialty Tools 1-800-525-2943 Page 393 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2372 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch LOCK. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Page 2615 A/F and 02 Sensor Identification Page 1779 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 1951 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2385 Intake Air Temperature Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1133 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2586 How To Read Ground Points Page 425 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Locations Page 159 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3176 Page 3003 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2964 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3238 Fuel Gauge Sender: Testing and Inspection INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3. 68 L: 57 L: If resistance value is not as specified, replace the sender gauge. Page 737 Page 3153 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. Page 3181 Fuel Injector: Service and Repair COMPONENTS REMOVAL 1. REMOVE THROTTLE BODY 2. DISCONNECT ENGINE WIRE Page 1273 Drive Belt: Service and Repair REMOVAL 1. REMOVE PS PUMP DRIVE BELT 2. REMOVE ENGINE UNDER COVER 3. LOOSEN IDLE PULLEY LOCK NUT Torque: 39 Nm (400 kg.cm, 29 ft.lb) 4. REMOVE COMPRESSOR DRIVE BELT Loosen drive belt tension by adjusting bolt and remove the drive belt. INSTALLATION 1. TIGHTEN IDLE PULLEY LOCK NUT TEMPORALLY Torque: 2.5 Nm (25 kg.cm, 22 in.lb) 2. INSTALL DRIVE BELT 3. USING ADJUSTING BOLT, ADJUST DRIVE BELT TENSION Drive belt tension New belt: 160 ± 25 lb Used belt: 100 ± 25 lb 4. TIGHTEN IDLE PULLEY LOCK NUT Torque: 39 Nm (400 kg.cm, 29 ft.lb) 5. INSTALL PS PUMP DRIVE BELT 6. INSTALL ENGINE UNDER COVER Restraints - OCS System Initialization Seat Occupant Sensor: Technical Service Bulletins Restraints - OCS System Initialization COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION SECTION: ELECTRICAL BULLETIN # 177 MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS DATE: MARCH 2010 Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System (OCS) will enable or disable the passenger front and side airbags based on seat occupancy passenger weight and seat belt latch engagement. If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a Diagnostic Trouble Code (DTC). NOTE: It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly. Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions with a Techstream Special Service Tool (SST) or capable diagnostic tester. Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER AIRBAG light to indicate incorrectly regardless of occupancy: ^ The OCS Electronic Control Unit (ECU) is replaced ^ Accessories such as a seatback tray are installed on the passenger seat ^ The passenger seat is removed and replaced or reinstalled ^ The vehicle is involved in an accident or collision Model-specific repair manuals can be accessed through the Technical Information System (TIS) www.techinfo.toyota.com Page 396 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3002 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 7 Underdash Fuses And Relays Details Page 2726 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 271 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 457 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 276 Acceleration/Deceleration Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2763 How To Read Ground Points Page 1526 Drive Belt: Tools and Equipment Toyota Serpentine Belt Wrench AST tool# TOY 1914 The TOY 1914 is a Toyota serpentine belt wrench that is equipped with 14mm and 19mm, 12 point secured attachments. Applications: 1998-2005 Corolla, 2004 Matrix, 2008 Highlander V6 (Non Hybrid), 2002 RAV4 and 4.7L/5.7L V8 used in Tundra and Sequoia through 2008. - Lightweight and Slim design - Equipped with 14mm and 19mm, 12 point securing attachments - Works on most Toyota applications (except Hybrids) Contact AST for pricing. Page 2965 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 43 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2987 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Page 2050 CHART 11 Page 299 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 892 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2388 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2297 Knock Sensor: Description and Operation The knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 2538 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Service and Repair Timing Chain Tensioner: Service and Repair For information regarding the service and repair of this compoent and the system that it is a part of please refer to Timing Chain; Service and Repair, Page 400 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2736 INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 2664 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Page 1668 Water Pump: Diagrams Page 76 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2039 Page 2287 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 1388 Locations System Diagnosis Air/Fuel Mixture: Testing and Inspection INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected HINT: All vacuum hoses for EGR systems, etc. should be properly connected. f. SFI system wiring connectors fully plugged. g. Ignition timing check correctly h. Transmission in neutral position i. Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft.) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When doing the 2 mode (idle and 2,500 rpm) test, these measurement order prescribed by the applicable local regulations. 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot according to the table. Page 2984 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1977 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2539 Page 870 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 3020 Step 4 INSPECTION PROCEDURE Page 1917 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. Page 2676 Oxygen Sensor: Description and Operation DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for the most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric air-fuel ratio. The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air-fuel ratio. This is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air-fuel ratio. When the air-fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN condition (small electromotive force: <0.45 V). When the air-fuel ratio is RICHER than the stoichiometric air-fuel ratio the oxygen concentration in the exhaust gas in reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive force: > 0.45 V). The ECM judges by the electromotive force from the oxygen sensor whether the air-fuel ratio is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to perform accurate air-fuel ratio control. The oxygen sensors include a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temp. of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Page 1308 Coolant: Fluid Type Specifications Coolant Type "Toyota Long Life Coolant" or Equivelant Ethylene-Glycol Coolant Do Not use alcohol type antifreezs or plain water alone. Page 705 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 1089 Transmission Mode Switch: Description and Operation CIRCUIT DESCRIPTION The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, L position and the lock-up patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position and other various sensors, the ECM switches the solenoid valves ON and OFF, and controls the transmission gear change and the lock-up clutch operation. Page 800 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2516 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 662 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Testing and Inspection Air Conditioning Switch: Testing and Inspection 1. INSPECT A/C INDICATOR OPERATION a. Connect the positive (+) lead from the battery to terminal 6 and the negative (-) lead to terminal 4. b. Push the A/C button in and then check that the indicator lights up. If operation is not as specified, replace the switch. 2. INSPECT DIMMING OPERATION a. Connect positive (+) lead from the battery to terminal 6 and negative (-) lead to terminal 4 and 1. b. Connect the positive (+) lead from the battery to terminal 3 and then check that the indicator dims. If operation is not as specified, replace the switch. 3. INSPECT A/C SWITCH CONTINUITY If operation is not as specified, replace the switch or test the bulb. Page 2417 Step 2 Step 3 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air-fuel ratio lean or rich, etc. at the time of the malfunction. Page 3232 Part 3 Of 4 Page 672 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3318 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Page 2040 Page 3282 a. Apply battery positive voltage across terminals STA and E1. b. Using an ohmmeter, check that there is continuity between terminals +B and FP. c. Apply battery positive voltage across terminals +B and FC. d. Check that there is continuity between terminals +B and FP. If operation is not as specified, replace the relay. 5. REINSTALL CIRCUIT OPENING RELAY 6. REINSTALL LOWER FINISH NO.1 PANEL Page 1106 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1255 Spark Plug: Application and ID Recommended Spark Plugs ND K16R-U NGK BKR5EYA Page 3328 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3011 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 809 How To Read Ground Points Locations Page 39 Electronic Brake Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Locations Antenna Relay: Locations Underhood Fuses And Relays Page 448 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2521 Data Link Connector: Testing and Inspection DLC3 INSPECTION Check the DLC3. The vehicle's ECM uses the ISO 9141-2 communication protocol. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. HINT: If your display shows "UNABLE TO CONNECT TO VEHICLE" when you have connected the cable of the OBD II scan tool or TOYOTA hand-held tester to DLC3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. - If communication is normal when the tool is connected to another vehicle, inspect DLC3 on the original vehicle. - If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself. Page 707 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 916 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2062 Locations Page 823 Locations Page 1020 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 2818 Page 2692 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Cooling System - Leak at Radiator Overflow Hose Coolant Reservoir: All Technical Service Bulletins Cooling System - Leak at Radiator Overflow Hose ENGINE EG012-99 November 5, 1999 Title: RADIATOR LEAK FROM OVERFLOW PIPE Models: '98 - '99 Tacoma Introduction Due to a casting mismatch, some 1998 - 1999 Tacomas may experience a leak from the coolant overflow pipe hose where it connects to the radiator upper tank. Affected Vehicles ^ 1998 - 1999 model year Tacoma produced between the VINs specified as shown. Parts Information Repair Procedure 1. Remove the overflow hose from the overflow pipe. 2. Using 240 grit sandpaper, smooth the outer surface of the overflow pipe on the upper radiator tank as shown. 3. Repeat using 400 grit sandpaper. 4. Reinstall hose utilizing the field fix Clip. NOTE: Do not use a knife for this procedure and do not sand in a horizontal direction. Warranty Information Page 2096 How To Read Ground Points Page 2508 How To Read Ground Points Page 278 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 730 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 150 Locations Page 2776 Specifications Firing Order: Specifications Firing order: 1-3-4-2 Cooling System - Leak at Radiator Overflow Hose Coolant Reservoir: Customer Interest Cooling System - Leak at Radiator Overflow Hose ENGINE EG012-99 November 5, 1999 Title: RADIATOR LEAK FROM OVERFLOW PIPE Models: '98 - '99 Tacoma Introduction Due to a casting mismatch, some 1998 - 1999 Tacomas may experience a leak from the coolant overflow pipe hose where it connects to the radiator upper tank. Affected Vehicles ^ 1998 - 1999 model year Tacoma produced between the VINs specified as shown. Parts Information Repair Procedure 1. Remove the overflow hose from the overflow pipe. 2. Using 240 grit sandpaper, smooth the outer surface of the overflow pipe on the upper radiator tank as shown. 3. Repeat using 400 grit sandpaper. 4. Reinstall hose utilizing the field fix Clip. NOTE: Do not use a knife for this procedure and do not sand in a horizontal direction. Warranty Information Page 2081 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2141 Vehicle Speed Sensor NO.2 Page 1182 3. INSPECT ACTUATOR OPERATION a. Connect lines via a relay as shown in the illustration, then check that the actuator fork shaft moves to 2WD position. b. Connect lines via a relay as shown in the illustration, then check that the actuator fork shaft moves to 4WD position. HINT: When inspecting the operation described above, use a heater main relay. If operation is not as specified, replace the actuator assembly. 4. INSPECT LIMIT SWITCH CONTINUITY Page 3159 Fuel: Specifications Fuel Type Unleaded fuel only, Research Octane Number 91 (Octane Rating 87) or higher. Page 1099 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3227 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Testing and Inspection Windshield Washer Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY w/ MIST: w/ INTERMITTENT: If continuity is not as specified, replace the switch. INSPECT INTERMITTENT OPERATION a. Turn the wiper switch to INT position. b. Turn the intermittent time control switch to FAST position. c. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. Page 2170 How To Read Ground Points Page 2491 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Locations EFI Main Relay: Locations Underhood Fuses And Relays Page 1718 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the engine wire protector from the 3 brackets. b. Disconnect the ECT sensor connector. c. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Locations Backup Lamp Relay: Locations Underhood Fuses And Relays Page 2667 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 633 Camshaft Position Sensor: Description and Operation The Camshaft position sensor (G signal) consists of a signal plate and pick up coil. The G signal plate has one tooth on its outer circumference and is mounted on the exhaust camshaft. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. Page 1848 How To Read Ground Points Page 2132 Step 2 Step 3 Page 3058 How To Read Ground Points Page 2450 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 683 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 937 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 989 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 537 Part 4 Of 4 Page 2393 Intake Air Temperature Sensor: Description and Operation The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. Figure 1 The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value. The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temp. sensor are connected in series. When the resistance value of the intake air temp. sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Diagram Information and Instructions Idle Air Control Valve: Diagram Information and Instructions Page 2973 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 983 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1704 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2180 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3063 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1918 INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 2834 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2312 Idle Speed: Testing and Inspection INSPECTION 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected HINT: All vacuum hoses for EGR system, etc. should be properly connected. f. SFI system wiring connectors fully plugged g. Ignition timing check correctly h. Transmission in neutral position 2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL 3. INSPECT IDLE SPEED a. Race the engine speed at 2,500 rpm for approx. 90 seconds. b. Check the idle speed. Idle speed: 650 - 750 rpm If the idle speed is not as specified, check the IAC valve, intake air leakage and SFI system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL Page 96 Underdash Fuses And Relays Details Page 302 Page 1141 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 178 Step 2 Step 3 Step 4 Step 5 Page 1537 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Page 2236 How To Read Ground Points Page 2368 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 37 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 772 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 622 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 274 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 1993 Intake Air Temperature Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2689 Engine Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 390 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 371 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Service and Repair Camshaft: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 98 Blower Motor Relay: Testing and Inspection INSPECT HEATER MAIN RELAY (Marking: HTR) CONTINUITY If continuity is not as specified, replace the relay. Page 1223 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 2008 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1178 Four Wheel Drive Selector Switch: Connector Views Page 1462 Connecting Rod: Specifications Connecting Rod Nut Connecting Rod Bearing Cap Nuts Step 1 .................................................................................................................................................. ............................... 45 N-m (460 kgf-cm, 33 ft-lbf) Step 2 .................................................................. ................................................................................................................................................. Turn 90° Page 2509 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1958 Page 1076 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1420 a. Set the control handle FREE. b. Remove the 6 cover mounting bolts and pull off the cover. Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.) HINT: At the time of installation, before installing the hub cover, apply the clutch spline with MP grease. c. Remove the gasket. 2. REMOVE FREE WHEEL HUB BODY a. Remove the 6 mounting nuts and washers. Torque: 31 Nm (315 kgf-cm, 23 ft. lbs.) b. Using a brass bar and hammer, tap on the bolts head and remove the 6 cone washers. c. Pull off the free wheel hub body. d. Remove the gasket. INSPECTION 1. INSPECT COVER, HANDLE AND SEAL Check the handle moves smoothly. 2. INSPECT INNER HUB Place the cover in the body and check that the inner hub turns smoothly. INSTALLATION Installation is in the reverse order of removal. Page 260 LH: If continuity is not as specified, replace the switch. RH: If continuity is not as specified, replace the switch. INSPECT DRIVER'S DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT PASSENGER'S DOOR UNLOCK DETECTION SWITCH CONTINUITY Page 912 How To Read Ground Points Page 1327 Fluid - M/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Page 1373 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (8Q kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Rear brake pressure HINT The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure 2 seconds after adjusting the specified fluid pressure. If the brake pressure is incorrect adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE (a) Adjust the length of the No.2 shackle. Low pressure - Lengthen A High pressure - Shorten A Initial set Adjustment range HINT: One turn of the nut changes the fluid pressure as shown in the following table. Rear brake pressure: (b) If the pressure cannot be adjusted by the No.2 shackle, raise or lower the valve body. Low pressure - Lower body High pressure - Raise body Page 1057 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1143 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Locations Relay Box: Locations Underhood Fuses And Relays Page 1632 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Page 423 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 157 How To Read Ground Points Page 2512 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 1864 Engine Control Module: Description and Operation DESCRIPTION The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to accomplish this control, the ECM relies on the input from a variety of engine operation sensors. The ECM compares input signals with those stored in memory to determine what steps should be taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM outputs the necessary signals to the fuel system, ignition system, emission control systems, etc.. Battery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is OFF for use by the DTC memory and air-fuel ratio adaptive control value memory, etc. Page 2613 Page 2147 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Service and Repair Valve Guide Seal: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Restraints - OCS System Initialization Seat Occupant Classification Module - Air Bag: Technical Service Bulletins Restraints - OCS System Initialization COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION SECTION: ELECTRICAL BULLETIN # 177 MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS DATE: MARCH 2010 Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System (OCS) will enable or disable the passenger front and side airbags based on seat occupancy passenger weight and seat belt latch engagement. If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a Diagnostic Trouble Code (DTC). NOTE: It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly. Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions with a Techstream Special Service Tool (SST) or capable diagnostic tester. Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER AIRBAG light to indicate incorrectly regardless of occupancy: ^ The OCS Electronic Control Unit (ECU) is replaced ^ Accessories such as a seatback tray are installed on the passenger seat ^ The passenger seat is removed and replaced or reinstalled ^ The vehicle is involved in an accident or collision Model-specific repair manuals can be accessed through the Technical Information System (TIS) www.techinfo.toyota.com Page 2559 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1912 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1974 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1383 Locations Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 3147 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2527 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2663 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 671 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1344 Engine Oil: Fluid Type Specifications Engine Oil API Classification .............................................................................................................................................. SJ Energy Conserving or ILAC Multigrade Above 0°F (-18°C) ................................................................ .................................................................................................................................... 10W-30 All Temperatures ...................................................................................................................................... .................................................................... 5w-30 Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Page 2573 Step 3 Step 4 Step 5 Page 1077 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Page 3275 Locations Page 2411 Page 2645 CHART 22 Page 738 O2S Application Table O2S Failure Threshold Charts Page 1463 Connecting Rod: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 2452 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 866 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1753 REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE RADIATOR GRILLE a. Remove the 4 screws, 2 clips and clearance lights. b. Remove the 2 filler. c. Remove the 11 clips and radiator grille. Page 2405 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 670 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3142 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Service and Repair Front Crankshaft Seal: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Oil Pump; Service and Repair. Page 982 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Locations Page 2547 Step 2 Step 3 Step 4 Step 5 Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 2871 CHART 15 Page 343 Wheel Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 3021 Transmission Position Switch/Sensor: Testing and Inspection Ford Made CIRCUIT DESCRIPTION When the shift position is put in positions except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM Step 1 Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 197 Locations Page 702 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1101 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2496 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 349 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 214 3. REMOVE AIRBAG SENSOR ASSEMBLY a. Disconnect the connector. NOTE: Remove the connector with the sensor assembly installed. b. Using a torx wrench remove the 3 screws and airbag sensor assembly. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) INSTALLATION NOTE: Never use SRS parts from another vehicle. When replacing parts, replace with new parts. - Never reuse the airbag sensor assembly involved in a collision when the airbag has deployed. - Never repair a sensor in order to reuse it. 1. INSTALL AIRBAG SENSOR ASSEMBLY a. Using a torx wrench, install the airbag sensor assembly with the 3 screws. Torx wrench: T40 (Part No.09042-00020 or locally manufactured tool) Torque: 20 N.m (205 kgf.cm, 15 ft.lbf) b. Connect the connector. NOTE: Installation of the connector is done after the sensor assembly has been installed. - Make sure the sensor assembly is installed to the specified torque. - If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one. - When installing the airbag sensor assembly, take care that the SRS wiring does not interfere with other parts and is not pinched between other parts. - After installation, shake the sensor assembly to check that there is no looseness. 2. INSTALL REMOVED PARTS Page 1333 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Page 2361 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 1982 Crankshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. Torque: Bolt A: 74.5 Nm (760 kg.cm, 55 ft.lb) Bolt B: 18 Nm (180 kg.cm, 13 ft.lb) 4. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5. REMOVE CRANKSHAFT POSITION SENSOR a. Remove the 2 bolts and crankshaft position sensor. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) b. Remove the O-ring. HINT: At the time of installation, please refer to the following items. - Always use a new O-ring when installing the crankshaft position sensor. - Apply a light coat of engine oil on the O-ring. INSTALLATION Installation is in the reverse order of removal. Page 2101 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1112 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch go on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM. Terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in D position. When the shift position is except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. Page 2993 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Diagram Information and Instructions Vapor Pressure Sensor: Diagram Information and Instructions Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions Ground Points Junction Block and Wire Harness Connector Page 2540 Engine Control Module: Connector Views Part 1 Of 2 Page 2698 Part 2 Of 2 Testing and Inspection Backup Lamp Switch: Testing and Inspection INSPECT BACK-UP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 761 CHART 26 Page 1863 Part 2 Of 2 Page 2971 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 436 Step 2 INSPECTION PROCEDURE Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. WIRING DIAGRAM Page 2734 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch LOCK. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Page 967 Crankshaft Position Sensor: Description and Operation Crankshaft position sensor (NE signal) consists of a signal plate and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle and the engine speed by the NE signals. Page 2831 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1763 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A," "B " and "C" are not deformed, cracked, or swollen. 3. Check that points "C" and "D" are not stuck together. 4. Apply engine coolant to points "B" and "C" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Compact Cap, 88 kPa Page 2886 CHART 27 Page 2626 Page 33 How To Read Ground Points Page 2399 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1601 17. REMOVE NO.1 TIMING CHAIN TENSIONER SLIPPER AND NO.1 VIBRATION DAMPER a. Remove the bolt and slipper. b. 2RZ-FE: Remove the 2 bolts and No.1 damper. c. 3RZ-FE: Remove the bolt, nut and No.1 damper. 18. 2RZ-FE: REMOVE CRANKSHAFT POSITION SENSOR ROTOR 19. 2RZ-FE: REMOVE TIMING CHAIN OIL JET Remove the bolt, oil jet and gasket. 20. REMOVE NO.2, NO.3 VIBRATION DAMPERS AND NO.2 CHAIN TENSIONER a. Install a pin to the No.2 chain tensioner and lock the plunger. b. Remove the bolt and No.2 damper. c. Remove the 2 bolts and No.3 damper. d. Remove the nut and No.2 chain tensioner. Page 2884 CHART 26 Page 1061 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2593 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2554 How To Read Ground Points Page 963 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1925 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2115 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2535 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2010 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 1946 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1904 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 236 Underdash Fuses And Relays Details Page 2051 CHART 12 CHART 13 Page 2643 Page 2900 Oxygen Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1140 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2294 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2921 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1544 TOY 730 - 73mm Toyota Oil Filter Wrench M 0219 - 74mm Oil Filter Wrench Testing and Inspection Control Module HVAC: Testing and Inspection INSPECT AMPLIFIER CIRCUIT a. Remove the glove compartment door. b. Disconnect the amplifier connector and inspect the connector on wire harness side, as shown in the chart. Test conditions: ^ Turn ignition switch to ON ^ Blower speed switch HI If the circuit is not as specified, inspect the circuits connected to other parts. c. Connect the connector to amplifier and inspect wire harness side connector from the back side, as shown in the chart. Test conditions ^ Running engine at idle speed ^ Blower speed switch at "HI" position ^ A/C switch ON ^ Temperature control lever at "COOL" position ^ Set on manifold gauge set If circuit is as specified, try replacing the amplifier with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. Page 1082 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1849 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2099 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2434 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2078 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2182 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 3351 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 728 Engine Bank Identification Page 2936 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2445 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 367 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2285 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3137 How To Read Ground Points Page 2797 Page 3276 EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION a. Apply battery positive voltage across terminals 86 and 85. b. Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Page 520 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 3299 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 3305 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Diagram Information and Instructions Vehicle Speed Sensor/Transducer - Cruise Control: Diagram Information and Instructions Page 2479 Starter Signal: Description and Operation Starter Signal When the engine is cranked, the intake airflow is slow, so fuel vaporization is poor A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after-start injection control. Page 1714 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1105 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 944 Page 893 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1274 Drive Belt: Tools and Equipment Toyota Serpentine Belt Wrench AST tool# TOY 1914 The TOY 1914 is a Toyota serpentine belt wrench that is equipped with 14mm and 19mm, 12 point secured attachments. Applications: 1998-2005 Corolla, 2004 Matrix, 2008 Highlander V6 (Non Hybrid), 2002 RAV4 and 4.7L/5.7L V8 used in Tundra and Sequoia through 2008. - Lightweight and Slim design - Equipped with 14mm and 19mm, 12 point securing attachments - Works on most Toyota applications (except Hybrids) Contact AST for pricing. Locations EFI Main Relay: Locations Underhood Fuses And Relays Page 966 Page 2562 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2894 How To Read Ground Points Page 2757 Camshaft Position Sensor: Testing and Inspection INSPECTION CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. b. Using an ohmmeter, measure the camshaft position sensor resistance between terminals. Resistance: Cold: 835 - 1,400 Ohms Hot: 1,060 - 1,645 Ohms If the resistance is not as specified, replace the camshaft position sensor. c. Connect the camshaft position sensor connector. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Page 1159 Page 2097 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 480 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 317 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2925 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2858 Page 1598 b. Remove the 4 bolts and A/C compressor bracket. 7. REMOVE GENERATOR, ADJUSTING BAR AND BRACKET a. Disconnect the generator connector. b. Remove the nut, and disconnect the generator wire and wire clip. c. Remove the lock, pivot bolts and the generator. d. Remove the bolt and adjusting bar. e. Remove the 3 bolts and generator bracket. 8. REMOVE CRANKSHAFT POSITION SENSOR a. Remove the 2 bolts and crankshaft position sensor. b. Remove the O-ring from the crankshaft position sensor. 9. 2WD: REMOVE STIFFENER PLATES Remove the 8 bolts and stiffener plates. 10. REMOVE FLYWHEEL HOUSING UNDER COVER AND DUST SEAL Vapor Pressure Sensor Vapor Pressure Sensor: Testing and Inspection Vapor Pressure Sensor 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V d. Turn the ignition switch to LOCK. e. Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under the following conditions: 1. Apply vacuum (2.0 kPa, 15 mmHg, 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kPa, 15 gf/sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8V d. Reconnect the vacuum hose to the vapor pressure sensor. Page 3229 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 523 Fuel Gauge Sender: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2616 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 1078 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2432 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1705 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 277 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2363 Mass Air Flow Meter: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2995 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 780 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2146 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2225 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1398 Locations Page 2031 Applicable Vehicles Page 88 Cruise Control Module: Testing and Inspection Denso Made System ECU Power Source Circuit (Inspection 1) CIRCUIT DESCRIPTION The ECU power source supplies power to the actuator and sensors, etc., when terminal GND and the cruise control ECU case are grounded. WIRING DIAGRAM Step 1 Page 2429 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 695 Page 2914 How To Read Ground Points Page 134 Locations Page 2635 CHART 10 Page 2090 Oxygen Sensor: Description and Operation DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for the most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric air-fuel ratio. The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air-fuel ratio. This is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air-fuel ratio. When the air-fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN condition (small electromotive force: <0.45 V). When the air-fuel ratio is RICHER than the stoichiometric air-fuel ratio the oxygen concentration in the exhaust gas in reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive force: > 0.45 V). The ECM judges by the electromotive force from the oxygen sensor whether the air-fuel ratio is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to perform accurate air-fuel ratio control. The oxygen sensors include a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temp. of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Page 1781 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2907 Page 89 Step 2 Step 3 INSPECTION PROCEDURE Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 3378 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1605 NOTICE: Check that No.1 cylinder is at TDC and that the weights of the No.1 and No.2 balance shafts are at the bottom side. 1. INSTALL NO.4 VIBRATION DAMPER Install the No.4 damper with the 2 bolts. 2. INSTALL NO.2 TIMING CHAIN, NO.2 CRANKSHAFT TIMING SPROCKET, BALANCE SHAFT DRIVE GEAR AND SHAFT a. Install the No.2 timing chain by matching its mark links with the timing marks on the No.2 crankshaft timing sprocket and balance shaft timing sprocket. b. Fit the other mark link of No.2 timing chain onto the sprocket behind the large timing mark of the balance shaft drive gear. c. Insert the balance shaft drive gear shaft through the balance shaft drive gear so that it fits into the thrust plate hole. Then align the small timing mark of the balance shaft drive gear with the timing mark of the balance shaft timing gear. d. Install the bolt to the balance shaft drive gear and tighten it. Torque: 25 Nm (250 kgf.cm, 18 ft. lbs.) e. Check that each timing mark is matched with the corresponding mark link. 3. INSTALL NO.2, NO.3 VIBRATION DAMPERS AND NO.2 CHAIN TENSIONER NOTICE: Assemble the chain tensioner with the pin installed, then remove the pin after assembly. When doing this, avoid pushing the No.2 vibration damper against the chain. a. Install the No.2 chain tensioner with the nut. Torque: 18 Nm (185 kgf.cm, 13 ft. lbs.) b. Install No.3 damper with the 2 bolts. Torque: 18 Nm (185 kgf.cm, 13 ft. lbs.) Page 1177 Page 2844 Applicable Vehicles Page 1801 b. Check the valve opening temperature. Valve opening temperature: 80 - 84°C (176 - 183°F) If the valve opening temperature is not as specified, replace the thermostat. c. Check the valve lift. Valve lift: 8 mm (0.31 inch) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. d. Check that the valve is fully closed when the thermostat is at low temperatures (below 40°C (104°F)). If not closed, replace the thermostat. INSTALLATION 1. PLACE THERMOSTAT IN WATER INLET HOUSING a. Install a new gasket to the thermostat. b. Align the jiggle valve of the thermostat with the protrusion of the water inlet housing, and insert the thermostat in the water inlet housing. HINT: The jiggle valve may be set within 15° of either side of the prescribed position. 2. CONNECT WATER INLET WITH LOWER RADIATOR HOSE Install the water inlet with the 2 nuts. HINT: Facing the top mark (protrusion) upward. Torque: 20 Nm (200 kgf.cm, 15 ft. lbs.) 3. FILL WITH ENGINE COOLANT 4. START ENGINE AND CHECK FOR LEAKS Page 1791 Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR a. Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 20 Nm (200 kg.cm, 14 ft.lb) b. Connect the ECT sensor connector. c. Install the engine wire protector to the 3 brackets. 5. REFILL ENGINE COOLANT Page 84 Cruise Control Module: Description and Operation Ford Made CIRCUIT DESCRIPTION The ECU power source supplies power to the actuator and sensors, etc.. When terminal GND and the cruise control ECU case are grounded. Page 2493 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2953 Step 2 Step 3 Page 555 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Locations Page 2490 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2422 How To Read Ground Points Page 243 Locations Page 2035 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 3220 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2796 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 3039 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 180 Engine Control Module: Service and Repair COMPONENTS REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE LOWER FINISH NO.2 PANEL 3. REMOVE ECM a. Disconnect the 4 ECM connectors. b. Remove the 2 bolts and ECM. INSTALLATION Installation is in the reverse order of removal. Page 1877 EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION a. Apply battery positive voltage across terminals 86 and 85. b. Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Page 2860 Page 2639 CHART 15 Page 1059 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 544 Relay Blocks Page 1949 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2778 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the engine wire protector from the 3 brackets. b. Disconnect the ECT sensor connector. c. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Page 2402 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 478 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 666 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Electrical - SRS And HV Wiring Repairs Battery System, Hybrid Drive: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs TITLE: SRS & HV WIRING REPAIRS SECTION: ELECTRICAL BULLETIN # 156 MODELS: ALL TOYOTA LEXUS and SCION MODELS DATE: AUGUST 2007 There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these circuits. Wiring diagrams are available through the Technical Information System (TIS) www.techinfo.toyota.com. If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and/or connectors require replacement of the affected harness. Follow all precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring and components. Page 723 Engine Bank Identification Page 3016 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch go on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM. Terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in D position. When the shift position is except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. Page 372 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Cooling System - Leak at Radiator Overflow Hose Radiator: All Technical Service Bulletins Cooling System - Leak at Radiator Overflow Hose ENGINE EG012-99 November 5, 1999 Title: RADIATOR LEAK FROM OVERFLOW PIPE Models: '98 - '99 Tacoma Introduction Due to a casting mismatch, some 1998 - 1999 Tacomas may experience a leak from the coolant overflow pipe hose where it connects to the radiator upper tank. Affected Vehicles ^ 1998 - 1999 model year Tacoma produced between the VINs specified as shown. Parts Information Repair Procedure 1. Remove the overflow hose from the overflow pipe. 2. Using 240 grit sandpaper, smooth the outer surface of the overflow pipe on the upper radiator tank as shown. 3. Repeat using 400 grit sandpaper. 4. Reinstall hose utilizing the field fix Clip. NOTE: Do not use a knife for this procedure and do not sand in a horizontal direction. Warranty Information Page 1807 Water Pump: Service and Repair Page 2622 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Denso Made Transmission Position Switch/Sensor: Testing and Inspection Denso Made CIRCUIT DESCRIPTION When the shift position is put in positions except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM Step 1 Page 2991 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1990 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Diagrams Timing Chain: Diagrams Page 185 Locations Page 3320 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 936 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2196 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2500 Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid .............................................................................................................................................. ............................................................ 2.5L (2.6 Qt) Page 1097 How To Read Ground Points Page 2295 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Service and Repair Cylinder Head Gasket: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Diagram Information and Instructions Fuel Gauge Sender: Diagram Information and Instructions Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Page 2597 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2941 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 898 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 528 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Locations Page 1786 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1789 Coolant Temperature Sensor/Switch (For Computer): Description and Operation A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the DTC P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). Page 3066 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. A/T - Delayed Upshift To O/D With Cruise Engaged Cruise Control Module: All Technical Service Bulletins A/T - Delayed Upshift To O/D With Cruise Engaged BULLETIN NUMBER: EL004-00 DATE: April 14, 2000 TITLE: DELAYED UPSHIFT TO OVERDRIVE WITH CRUISE CONTROL ENGAGED MODELS: '98 - '99 Tacoma INTRODUCTION A revised cruise control ECU is available for 1998-1999 Tacoma trucks with automatic transmissions. While cruise control is engaged, the new ECU improves the upshift delay from 3rd to 4th gear after the vehicle comes over the crest of a hill. To correct the concern, replace the cruise control ECU and perform the cable adjustment procedure as shown in this bulletin. APPLICABLE VEHICLES: 1998 - 1999 (4 cylinder) Tacoma Trucks with automatic transmissions produced before the VIN's listed in the illustration. PRODUCTION CHANGE INFORMATION PARTS INFORMATION WARRANTY INFORMATION APPLICABLE WARRANTY*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. * Warranty application is limited to correction of a problem based upon a customer's specific complaint. REPAIR PROCEDURE: Testing and Inspection Power Mirror Switch: Testing and Inspection INSPECT MIRROR SWITCH CONTINUITY Left side: Right side: If continuity is not as specified, replace the switch. Page 1216 b. Loosen the tie rod end lock nuts. c. Turn the right and left rack ends by an equal amount to adjust the toe-in. HINT: Try to adjust the toe-in to the center of the specified value. d. Make sure that the lengths of the right and left rack ends are the same. Rack end length difference: 1.5 mm (0.059 inch) or less e. Tighten the tie rod end lock nuts. Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.) f. Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. g. Inspect the wheel angle. Turn the steering wheel fully and measure the turning angle. Wheel turning angle: If the right and left wheel turning angles differ from the specified value, readjust the toe-in and wheel angle within the specified value. At this time, the right and left error lengths of the rack end may be less than 1.5 mm (0.059 inch). Page 3309 Mass Air Flow Meter: Description and Operation The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Diagram Information and Instructions Brake Signal: Diagram Information and Instructions Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Page 775 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2220 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1933 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2904 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 957 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2487 How To Read Ground Points Page 3035 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2269 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2284 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1981 Crankshaft Position Sensor: Testing and Inspection NOTE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10 ° C (14 ° F) to 50 °C (122 °F) and "Hot" is from 50 °C (122°F) to 100 °C (212 °F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (NE(+) and NE(-)): Cold: 1,630 - 2,740 Ohms Hot: 2,065 - 3,225 Ohms If the resistance is not as specified, replace the crankshaft position sensor. Page 1172 Page 2064 CHART 25 Page 1664 - Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 9. REINSTALL CYLINDER HEAD COVER 10. RECONNECT ENGINE WIRE 11. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 12. REINSTALL PCV HOSES 13. REINSTALL INTAKE AIR CONNECTOR Page 783 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2001 Intake Air Temperature Sensor: Description and Operation The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. Figure 1 The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value. The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temp. sensor are connected in series. When the resistance value of the intake air temp. sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 1622 a. Check heated oxygen sensor operation. b. Check and correct the cause if necessary. Page 2859 Page 2019 Page 2478 Page 366 How To Read Ground Points Specifications Engine Oil Pressure: Specifications Oil Pressure at Idle 29 kPa (4.3 psi) or more Oil Pressure at 3000 rpm 245-490 kPa (36-71 psi) Page 1795 W/O Tachometer HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. This circuit includes the diode. If resistance value is not as specified, replace the receiver gauge. Page 919 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2587 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 90 ECU Power Source Circuit (Inspection 2) CIRCUIT DESCRIPTION The ECU power source supplies power to the actuator and sensors, etc.. When terminal GND and the cruise control ECU case are grounded. WIRING DIAGRAM Step 1 Page 1931 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 558 Page 427 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 747 CHART 14 Page 2749 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1294 Hose/Line HVAC: Tools and Equipment A/C Clamp Remover AST tool# TOY 200 Page 453 Cruise Control Switch: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 903 Page 2628 Page 1850 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1495 - Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 9. REINSTALL CYLINDER HEAD COVER 10. RECONNECT ENGINE WIRE 11. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 12. REINSTALL PCV HOSES 13. REINSTALL INTAKE AIR CONNECTOR Page 2838 Knock Sensor: Description and Operation The knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Page 1934 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2634 CHART 8 CHART 9 Page 691 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Locations Locations Tail Lamp Relay: Locations Underhood Fuses And Relays Diagrams Fuel Supply Line: Diagrams COMPONENTS CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. Page 526 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3246 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2563 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1536 Engine Oil: Fluid Type Specifications Engine Oil API Classification .............................................................................................................................................. SJ Energy Conserving or ILAC Multigrade Above 0°F (-18°C) ................................................................ .................................................................................................................................... 10W-30 All Temperatures ...................................................................................................................................... .................................................................... 5w-30 Page 450 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1992 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2915 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2816 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1174 Page 2750 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1007 Ignition Switch: Testing and Inspection INSPECT IGNITION SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 3089 Exhaust Gas Recirculation Gas Temperature Sensor: Testing and Inspection COMPONENTS INSPECTION 1. REMOVE EGR VALVE 2. REMOVE EGR GAS TEMPERATURE SENSOR 3. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 64 - 97 kohms at 50 °C (122 °F) 11 - 16 kohms at 100 °C (212 °F) 2 - 4 kohms at 150 °C (302 °F) If the resistance is not as specified, replace the sensor. 4. REINSTALL EGR GAS TEMPERATURE SENSOR 5. REINSTALL EGR VALVE Page 2435 Specifications Wheel Fastener: Specifications Hub/Lug Nut ........................................................................................................................................ ................................................... 110 Nm (83 ft. lbs.) Page 2938 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2711 Locations Page 774 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2292 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Page 81 Page 2849 Applicable Vehicles Page 1930 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1179 Page 2625 Page 2766 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 531 Part 2 Of 4 Page 166 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2289 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Locations Page 3070 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 713 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2197 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2425 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 451 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 3346 How To Read Ground Points Page 2704 Step 2 Step 3 Step 4 Step 5 Page 253 Locations Page 2824 How To Read Ground Points Page 196 Underdash Fuses And Relays Details Page 1854 Engine Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 127 Underdash Fuses And Relays Details Page 309 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1790 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the engine wire protector from the 3 brackets. b. Disconnect the ECT sensor connector. c. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Page 1354 Power Steering Fluid: Service Precautions Use automatic transmission fluid Dexron II or Dexron III. Page 2658 CHART 30 Page 814 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Specifications Water Pump: Specifications Water Pump Bolts 14 mm head bolt 24.5 Nm (18 ft.lb) 12 mm head bolt 8.9 Nm (78 in.lb) Page 388 How To Read Ground Points Page 438 Step 3 Step 4 INSPECTION PROCEDURE Page 1587 Camshaft Gear/Sprocket: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 2877 CHART 22 Page 620 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3111 Vapor Pressure Sensor: Testing and Inspection VSV For Vapor Pressure Sensor 1. REMOVE VSV a. Disconnect the connector and 3 EVAP hoses from the VSV. b. Remove the bolt and VSV. 2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 37 - 44 ohm at 20 °C (68 °F) If there is no continuity, replace the VSV. 3. INSPECT VSV FOR GROUND Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. 4. INSPECT VSV OPERATION Service and Repair Valve Guide: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Page 1046 Step 2 Step 3 INSPECTION PROCEDURE Page 2366 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2052 CHART 14 Page 3317 How To Read Ground Points Page 901 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2116 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2575 Idle Air Control Valve: Component Tests and General Diagnostics Component Inspection 1. INSPECT IAC VALVE RESISTANCE NOTE: "Cold" end "Hot" in the following sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO). Resistance: Cold: 17.0 - 24.5 ohms Hot: 21.5 - 28.5 ohms If resistance is not as specified, replace the IAC valve 2. INSPECT IAC VALVE OPERATION a. Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSC, and check that the valve is closed. b. Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSO, and check that the valve is open. On-Vehicle Inspection INSPECT IAC VALVE OPERATION a. Initial conditions: - Engine at normal operating temperature - Idle speed checked correctly - Transmission in neutral position Page 1311 Coolant: Service and Repair REPLACEMENT 1. REPLACE ENGINE COOLANT a. Remove the radiator cap. WARNING: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. b. Drain the coolant from the radiator and cylinder drain plugs. (Engine coolant drain plug at the right of cylinder block.) c. Close the drain plugs. Torque: Engine coolant drain plug: 24.5 Nm (250 kgf.cm, 18 ft. lbs.) 2. FILL ENGINE COOLANT a. Slowly fill the system with coolant. - Use a good brand of ethylene-glycol base coolant and mix it according to the manufacturer's directions. - Using coolant which includes more than 50 % ethylene-glycol (but not more than 70 %) is recommended. NOTICE: ^ Do not use an alcohol type coolant. ^ The coolant should be mixed with demineralized water or distilled water. Capacity (w/ Heater): 2WD: M/T: 8.0 liters (8.5 US qts., 7.0 Imp. qts.) A/T: 7.8 liters (8.2 US qts., 6.9 Imp. qts.) 4WD: M/T: 8.3 liters (8.8 US qts., 7.2 Imp. qts.) A/T: 8.2 liters (8.7 US qts., 7.2 Imp. qts.) b. Reinstall the radiator cap. c. Start the engine, and bleed the cooling system. d. If necessary, refill engine coolant into the radiator reservoir until it is "FULL" line. 3. CHECK ENGINE COOLANT FOR LEAKS Page 894 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 655 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the engine wire protector from the 3 brackets. b. Disconnect the ECT sensor connector. c. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Page 374 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2933 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 739 CHART 1 Page 1851 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Page 3104 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2531 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2107 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 956 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2079 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 560 Key Reminder Switch: Testing and Inspection INSPECT IGNITION SWITCH CONTINUITY INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2263 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2177 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1318 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................................... .................................. DEXRON II or DEXRON III Page 1056 How To Read Ground Points Page 3264 Idle Air Control Valve: Component Tests and General Diagnostics Component Inspection 1. INSPECT IAC VALVE RESISTANCE NOTE: "Cold" end "Hot" in the following sentences express the temperature of the coils themselves. "Cold" is from -10 °C (14 °F) to 50 °C (122 °F) and "Hot" is from 50 °C (122 °F) to 100 °C (212 °F). Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO). Resistance: Cold: 17.0 - 24.5 ohms Hot: 21.5 - 28.5 ohms If resistance is not as specified, replace the IAC valve 2. INSPECT IAC VALVE OPERATION a. Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSC, and check that the valve is closed. b. Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSO, and check that the valve is open. On-Vehicle Inspection INSPECT IAC VALVE OPERATION a. Initial conditions: - Engine at normal operating temperature - Idle speed checked correctly - Transmission in neutral position Page 3007 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Page 80 Cruise Control Module: Electrical Diagrams Page 2517 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 632 Page 2943 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2155 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Standard Value of ECM Terminals Engine Control Module: Testing and Inspection Standard Value of ECM Terminals Part 1 Of 2 Page 2502 Crankshaft Position Sensor: Testing and Inspection NOTE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10 ° C (14 ° F) to 50 °C (122 °F) and "Hot" is from 50 °C (122°F) to 100 °C (212 °F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (NE(+) and NE(-)): Cold: 1,630 - 2,740 Ohms Hot: 2,065 - 3,225 Ohms If the resistance is not as specified, replace the crankshaft position sensor. Page 3349 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2212 INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 2273 Crankshaft Position Sensor: Testing and Inspection NOTE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10 ° C (14 ° F) to 50 °C (122 °F) and "Hot" is from 50 °C (122°F) to 100 °C (212 °F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (NE(+) and NE(-)): Cold: 1,630 - 2,740 Ohms Hot: 2,065 - 3,225 Ohms If the resistance is not as specified, replace the crankshaft position sensor. Page 2137 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES. 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH. Torque: Nut: 6.9 Nm (70 kgf cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR CONNECT 2 OIL COOLER PIPES Page 3330 Page 1115 Step 2 Step 3 Page 2770 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2532 Engine Control Module: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1432 Towing Information: Technical Service Bulletins Vehicle - Towing Guide ACCESSORIES AX004-99 March 19, 1999 Title: TOYOTA "DINGHY" TOWING GUIDE Models: All Models Introduction: The following chart indicates which Toyota vehicles can be Dinghy towed (towed with four wheels on the ground) behind a Motorhome. CAUTION: Dinghy towing 6 vehicle behind a Motorhome requires special towing equipment and accessories. Please see your Motorhome Manufacturer / Service Outlet for recommended towing equipment. Affected Vehicles - All Models Vehicles that are Dinghy towable will not sustain internal damage to the transmission or transfer components. The transmission must be placed in the "neutral" position when Dinghy towing. Dinghy towing these vehicles does not eliminate the possibility of damage to other vehicle systems (Body, Chassis, Electrical Systems, etc.). Warranty Information Page 993 Knock Sensor: Testing and Inspection 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR a. Disconnect the knock sensor connector. b. Using SST remove the knock sensor. SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Using SST, install the knock sensor. SST 09816-30010 Torque: 44 Nm (450 kg.cm, 33 ft.lb) b. Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 Nm (200 kg.cm, 14 ft.lb) 7. REINSTALL STARTER Page 2808 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 618 How To Read Ground Points Page 3375 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection INSPECT LOW OIL PRESSURE WARNING LIGHT a. Disconnect the connector from the warning switch and ground terminal on the wire harness side connector. b. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. Page 1655 Compression Check: Testing and Inspection INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. REMOVE SPARK PLUGS 5. CHECK CYLINDER COMPRESSION PRESSURE a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle c. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. d. Repeat steps a. through c. for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,230 kPa (12.5 kgf/cm2, 178 psi) or more Minimum pressure: 880 kPa (9.0 kgf/cm2, 127 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less e. If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps a. through c. for cylinders with low compression. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damage. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 6. REINSTALL SPARK PLUGS Torque: 19 Nm (200 kgf.cm, 14 ft. lbs.) 7. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 8. REINSTALL INTAKE AIR CONNECTOR Page 2847 A/F and 02 Sensor Identification Page 113 Backup Lamp Relay: Testing and Inspection INSPECT BACK-UP LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 2272 Crankshaft Position Sensor: Description and Operation Crankshaft position sensor (NE signal) consists of a signal plate and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle and the engine speed by the NE signals. Page 2864 CHART 5 CHART 6 Page 924 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm Page 2219 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1663 - Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch). c. Install a new adjusting shim. - Place a new adjusting shim on the valve lifter. Page 2828 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2918 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2000 Page 1038 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3219 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1393 Locations Page 535 Part 2 Of 4 Diagrams Page 2839 Knock Sensor: Testing and Inspection 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR a. Disconnect the knock sensor connector. b. Using SST remove the knock sensor. SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Using SST, install the knock sensor. SST 09816-30010 Torque: 44 Nm (450 kg.cm, 33 ft.lb) b. Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 Nm (200 kg.cm, 14 ft.lb) 7. REINSTALL STARTER Page 2646 Page 1180 Four Wheel Drive Selector Switch: Description and Operation The 4WD ECU operates the 2-4 select motor in accordance with the conditions of the 2-4 select SW, the detection SW (Transfer 4WD position) and the detection SW (Transfer L4 position). It also controls the range over which shifting from H2 to H4 is possible based ON the vehicle speed sensor. If the 2-4 select SW is pushed in while shifting is prohibited, it causes the 4WD indicator light to flash and sounds a warning buzzer to inform the driver. The warning buzzer is built into the ECU. The operation of the ECU is as follows. 2-4 SELECT SYSTEM The 2-4 select system selects between 2WD and 4WD by means of a 2-4 select SW located in the transfer shift lever knob which provides good operability. This system uses an ECU which drives the 2-4 select motor in accordance with signals from various sensors and accomplishes shifting between 2WD and 4WD. Shifting between H4 to L4 is accomplished by operating the transfer shift lever as before. This system also permits shifting between H2 and H4 without first shifting to H4. All models equipped with 2-4 select system are also equipped with the add, explained later. 1. Shifting from H4 to H2 When the 2-4 select SW is turned OFF. a signal is input to the 2-4 select motor from the 4WD ECU, activating the 2-4 select motor so that the transfer changes to 2WD (H2 position). At this time, the detection SW (Transfer 4WD position) and ADD indicator SW are OFF, so the 4WD indicator light goes OFF. 2. Shifting from H2 to H4 (During normal driving) When the 2-4 select SW is turned ON, a signal is input to the 2-4 select motor from the 4WD ECU, activating the 2-4 select motor so that the transfer changes to 4WD (H4 position) 3. Shifting from H2 to H4 (High speed driving) The vehicle speed within below approx. 100 kph, 62 mph. activating the 2-4 select motor so that the transfer changes to 4WD (H4 position) The 4WD ECU stops the signal to the 2-4 select motor with the signal from the vehicle speed sensor. At the same time, it causes the 4WD indicator light to light up and the warning buzzer inside the 4WD ECU to sound. 4. Shifting to L4 When the transfer shift lever is moved to L4 position, the transfer changes to LO position. This turns the detection SW (Transfer L4 position) ON so regardless of whether the 2-4 select SW is ON or OFF, a signal is input to the 2-4 select motor from the 4WD ECU, activating the 2-4 select motor so that the transfer changes to 4WD (L4 position) in LO condition. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Page 757 Page 932 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 552 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2246 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2362 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1560 Intake Manifold: Testing and Inspection For information regarding the testing and inspection of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair; Disassembly and Reassembly. Page 2260 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 969 Crankshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. Torque: Bolt A: 74.5 Nm (760 kg.cm, 55 ft.lb) Bolt B: 18 Nm (180 kg.cm, 13 ft.lb) 4. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5. REMOVE CRANKSHAFT POSITION SENSOR a. Remove the 2 bolts and crankshaft position sensor. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) b. Remove the O-ring. HINT: At the time of installation, please refer to the following items. - Always use a new O-ring when installing the crankshaft position sensor. - Apply a light coat of engine oil on the O-ring. INSTALLATION Installation is in the reverse order of removal. Page 313 Differential Lock Switch: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1715 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 45 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Page 1940 Camshaft Position Sensor: Service and Repair COMPONENTS REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. b. Remove the bolts and camshaft position sensor. Torque: 5.4 Nm (55 kg.cm, 48 in.lb) INSTALLATION Installation is in the reverse order of removal. Bleeding the Brake System Brake Bleeding: Service and Repair Bleeding the Brake System BLEEDING HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the air from the system. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. Fill Brake Reservoir 1. FILL BRAKE RESERVOIR WITH BRAKE FLUID Check the fluid leveling the reservoir after bleeding each wheel. Fluid: SAE J1703 or FMVSS No. 116 DOT 3 2. BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. a. Disconnect the brake lines from the master cylinder. b. Slowly depress the brake pedal and hold it. c. Block off the outlet plug with your finger, and release the brake pedal. d. Repeat (b) and (c) 3 or 4 times. Page 1084 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1231 Idle Speed: Testing and Inspection INSPECTION 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected HINT: All vacuum hoses for EGR system, etc. should be properly connected. f. SFI system wiring connectors fully plugged g. Ignition timing check correctly h. Transmission in neutral position 2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL 3. INSPECT IDLE SPEED a. Race the engine speed at 2,500 rpm for approx. 90 seconds. b. Check the idle speed. Idle speed: 650 - 750 rpm If the idle speed is not as specified, check the IAC valve, intake air leakage and SFI system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL Page 2686 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Page 3043 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2743 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3377 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1068 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2016 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 848 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 394 Brake Switch (Cruise Control): Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2687 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 3210 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). c. Observe these precautions when removing and installing the injectors. 1. Never reuse the O-ring. 2. When placing a new O-ring on the injector, take care not to damage it in any way. 3. Coat a new O-ring with spindle oil or gasoline before installing-never use engine, gear or brake oil. d. Install the injector to the delivery pipe and cylinder head as shown in the illustration. e. Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. 1. Connect the TOYOTA hand-held tester to the DLC3. 2. Turn ignition switch ON and TOYOTA hand-held tester main switch ON. 3. Select the active test mode on the TOYOTA hand-held tester. 4. Please refer to the TOYOTA hand-held tester operator's manual for further details. Page 2349 - Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch). c. Install a new adjusting shim. - Place a new adjusting shim on the valve lifter. Page 2898 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2365 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1217 Alignment: Tools and Equipment Equipment Tire pressure gauge Dial indicator with magnetic base Wheel balancer Page 2021 Knock Sensor: Testing and Inspection 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR a. Disconnect the knock sensor connector. b. Using SST remove the knock sensor. SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Using SST, install the knock sensor. SST 09816-30010 Torque: 44 Nm (450 kg.cm, 33 ft.lb) b. Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 Nm (200 kg.cm, 14 ft.lb) 7. REINSTALL STARTER Page 2862 CHART 1 Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Specifications Piston: Specifications 2RZ-FE Engine Piston Diameter Std. 94.923-94.933 mm O/S 0.50 95.423-95.433 mm Piston Oil Clearance Std. 0.057-0.080 mm 3RZ-FE Engine Piston Diameter Std. 94.933-94.943 mm O/S 0.50 95.433-95.443 mm Piston Oil Clearance Std. 0.047-0.070 mm Page 2205 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3286 Underdash Fuses And Relays Details Page 1929 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 812 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 3006 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that continuity exists between terminals with the switch ON (switch pin released). b. Check that no continuity exists between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Page 1214 b. Adjust the camber and caster by front and/or rear adjusting cams (See adjustment chart). HINT: Try to adjust the camber and caster to the center of the specified values. c. How to read adjustment chart. 1. Find the wheel alignment standard value applicable for the particular model. 2. Mark the selected standard value on the adjustment chart. Example: Camber: 0°10'(0.17°) Caster: 1°40' (1.67°) Page 907 INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 77 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Testing and Inspection Parking Brake Warning Switch: Testing and Inspection INSPECT PARKING BRAKE SWITCH CONTINUITY a. Check that continuity exists between terminals with the switch ON (switch pin released). b. Check that no continuity exists between terminals with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch. Page 751 CHART 20 Page 899 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2415 Step 2 Step 3 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air-fuel ratio lean or rich, etc. at the time of the malfunction. Page 347 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1032 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 344 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 3150 Page 2569 Idle Air Control Valve: Description and Operation The rotary solenoid type IAC valve is located on the throttle body and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle-up and provide feedback for the target idling speed. Page 3319 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 945 Page 2792 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 958 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2753 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2249 Page 725 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 938 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 750 CHART 18 CHART 19 Page 1124 Vehicle Speed Sensor NO.2 Page 980 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2036 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 369 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 538 Fuel Gauge Sender: Testing and Inspection INSPECT FUEL SENDER GAUGE RESISTANCE Measure the resistance between terminals 2 and 3. 68 L: 57 L: If resistance value is not as specified, replace the sender gauge. Page 3237 Part 4 Of 4 Page 1212 2. INSTALL CAMBER-CASTER-KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION Camber, caster and steering axis inclination: RZN161L model RZN 171L model RZN191L model RZN196L model VZN170L model Testing and Inspection Idle Up Control Valve: Testing and Inspection INSPECTION 1. TURN AIR CONDITIONING SWITCH OFF 2. CHECK IDLE-UP a. Start engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine rpm decreases when the vacuum hose of the air control valve is pinched. d. Check that the engine rpm increases when the hose is released. Page 1672 6. w/PS: REMOVE DRIVE BELT FOR PS PUMP Loosen the lock bolt and adjusting bolt, and remove the drive belt. 7. REMOVE FAN SHROUDS a. Remove the 2 clips and No.2 fan shroud. b. Remove the 4 bolts and No.1 fan shroud. 8. w/ A/C: REMOVE DRIVE BELT FOR A/C COMPRESSOR Loosen the idler pulley nut and adjusting bolt, and remove the drive belt. 9. REMOVE DRIVE BELT FOR GENERATOR, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY a. Stretch the belt and loosen the water pump pulley nuts. b. Loosen the lock, pivot and adjusting bolts of the generator, and remove the drive belt. c. Remove the 4 water pump pulley nuts. Torque: 21 Nm (210 kgf.cm, 16 ft. lbs.) d. Pull out the fan together with the fluid coupling and water pump pulley. 10. REMOVE WATER PUMP Remove the 10 bolts, water pump and gasket. Torque: 14 mm head bolt: 24.5 Nm (250 kgf.cm, 18 ft. lbs.) 12 mm head bolt: 8.9 Nm (90 kgf.cm, 78 inch lbs.) HINT: At the time of installation, please refer to the following items. Use a new gasket. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 517 How To Read Ground Points Page 2474 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1045 Step 1 Page 1600 a. Remove the 2 water bypass pipe nuts. b. Remove the 2 timing chain cover bolts. c. Remove the 9 bolts and 2 nuts. d. Using a plastic faced hammer, loosen the chain cover and remove the timing chain cover and 3 gasket. 15. REMOVE NO.1 TIMING CHAIN AND CAMSHAFT TIMING GEAR 16. REMOVE CRANKSHAFT TIMING GEAR HINT: If necessary, remove the gear with SST and crankshaft pulley bolt. SST 09950-40011 (09951-04010, 09952-04010, 09953-04010, 09954-04010, 09955-04060) Page 918 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1120 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES. 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH. Torque: Nut: 6.9 Nm (70 kgf cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR CONNECT 2 OIL COOLER PIPES Page 2903 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2541 Part 2 Of 2 Page 959 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1069 Page 1901 How To Read Ground Points Page 947 Camshaft Position Sensor: Testing and Inspection INSPECTION CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. b. Using an ohmmeter, measure the camshaft position sensor resistance between terminals. Resistance: Cold: 835 - 1,400 Ohms Hot: 1,060 - 1,645 Ohms If the resistance is not as specified, replace the camshaft position sensor. c. Connect the camshaft position sensor connector. Page 1164 Page 630 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 1755 2. REMOVE RADIATOR SUPPORTS Remove the 4 screws and 2 radiator supports. HINT: At the time of assembly, please refer to the following items. Insert the tabs the radiator upper tank through the radiator support holes. Torque: 5.5 Nm (55 kgf.cm, 49 inch lbs.) REASSEMBLY Reassembly is in the reverse order of disassembly. INSTALLATION Installation is in the reverse order of removal. Page 223 Underdash Fuses And Relays Details Page 935 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2438 Camshaft Position Sensor: Testing and Inspection INSPECTION CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. b. Using an ohmmeter, measure the camshaft position sensor resistance between terminals. Resistance: Cold: 835 - 1,400 Ohms Hot: 1,060 - 1,645 Ohms If the resistance is not as specified, replace the camshaft position sensor. c. Connect the camshaft position sensor connector. Page 604 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2917 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2668 Oxygen Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1853 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2641 CHART 18 CHART 19 Page 2499 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 133 Underdash Fuses And Relays Details Page 2084 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Diagram Information and Instructions Brake Switch (Cruise Control): Diagram Information and Instructions Page 2751 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2577 Idle Air Control Valve: Service and Repair COMPONENTS REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket. INSTALLATION 1. INSTALL IAC VALVE Page 1806 WATER PUMP AND RELATED COMPONENTS Page 2444 How To Read Ground Points Page 442 Step 3 Step 4 INSPECTION PROCEDURE Testing and Inspection Catalytic Converter: Testing and Inspection 1. CHECK TWC FOR DENTS OR DAMAGE If any part of the protector is damaged or dented to the extent that it touches the three-way catalytic converter, repair or replace it. 2. CHECK EXHAUST PIPE CONNECTIONS FOR LOOSENESS OR DAMAGE 3. CHECK EXHAUST PIPE CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE 4. CHECK HEAT INSULATOR FOR DAMAGE 5. CHECK FOR ADEQUATE CLEARANCE BETWEEN TWC AND HEAT INSULATOR Page 1857 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2286 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 3197 Fuel Pump Relay: Testing and Inspection COMPONENTS INSPECTION 1. REMOVE LOWER FINISH NO.1 PANEL 2. REMOVE CIRCUIT OPENING RELAY 3. INSPECT CIRCUIT OPENING RELAY CONTINUITY a. Using and ohmmeter, check that there is continuity between terminals STA and E1. If there is no continuity, replace the relay. b. Check that there is continuity between terminals +B and FC. If there is no continuity, replace the relay. c. Check that there is no continuity between terminals +B and FP. If there is continuity, replace the relay. 4. INSPECT CIRCUIT OPENING RELAY OPERATION Page 3097 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Diagram Information and Instructions Four Wheel Drive Selector Switch: Diagram Information and Instructions Connector Joining Wire Harness and Wire Harness Ground Points Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Page 2755 Specifications Compression Check: Specifications Compression Pressure 1230 kPa (178 psi) or more Minimum Pressure 880 kPa (127 psi) Difference Between Each Cylinder 98 kPa (14 psi) or less Page 2988 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 626 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1673 INSPECTION 1. INSPECT WATER PUMP a. Visually check the air hole and drain hole for coolant leakage. If leakage is found, replace the water pump. b. Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. INSPECT FLUID COUPLING a. Remove the 4 nuts and fan from the fluid coupling. b. Check the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling. c. Install the fan and fluid coupling with the 4 nuts. Torque: 5.5 Nm (55 kgf.cm, 49 inch lbs.) INSTALLATION Installation is in the reverse order of removal. Page 280 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3226 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 786 Oxygen Sensor: Testing and Inspection INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS a. Disconnect the heated oxygen sensor connector. b. Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: Bank 1 Sensor 1: 11 - 16 ohm at 20 °C (68 °F) Bank 1 Sensor 2: 11 - 16 ohm at 20 °C (68 °F) If resistance is not as specified, replace the heated oxygen sensor. c. Reconnect the heated oxygen sensor connector. Page 1644 If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. f. Connect the high-tension cords to the ignition coils. 1. Assemble the holder and grommet. 2. Align the spline of the ignition coil with the spline of the holder, and push in the cord. NOTE: Check that the holder is correctly installed to the grommet and ignition coil as shown in the illustration. 3. Check that the lock claw of the holder is engaged by lightly pulling the holder. g. Connect the high-tension cords to the spark plugs. Secure the high-tension cords with the clamps as shown in the illustration. h. Install the intake air connector. i. Install the air cleaner cap and MAF meter assembly. Page 46 Page 315 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1861 Specifications Tires: Specifications Cold Tire Inflation Pressure: P225/75R15: Front .................................................................................................................................................... ............................................... 180 kPa (26 psi) Rear .......................................................................... .......................................................................................................................... 200 kPa (29 psi) P265/75R15: Front .................................................................................................................................................... ............................................... 180 kPa (26 psi) Rear .......................................................................... .......................................................................................................................... 180 kPa (26 psi) 31 x 10.5R15LT: Front .................................................................................................................................................... ............................................... 180 kPa (26 psi) Rear .......................................................................... .......................................................................................................................... 200 kPa (29 psi) Vapor Pressure Sensor Vapor Pressure Sensor: Testing and Inspection Vapor Pressure Sensor 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V d. Turn the ignition switch to LOCK. e. Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under the following conditions: 1. Apply vacuum (2.0 kPa, 15 mmHg, 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kPa, 15 gf/sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8V d. Reconnect the vacuum hose to the vapor pressure sensor. Page 3374 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1088 Page 2875 Page 1079 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2878 Page 2654 CHART 27 Page 2963 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2945 Transmission Position Switch/Sensor: Electrical Diagrams Page 1858 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 440 Step 2 Step 3 INSPECTION PROCEDURE Clutch Switch Circuit CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the cruise control ECU. When the signal is input to the cruise control ECU during cruise control driving, the cruise control ECU cancels cruise control. Engine Brake Signal: Testing and Inspection Engine CIRCUIT DESCRIPTION This signal is used to detect when the brakes have been applied. The BK signal voltage is the same as the voltage supplied to the stop lights. The BK signal is used mainly to control the fuel cut-off engine speed. (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.) DETECTING CONDITIONS WIRING DIAGRAM Step 1 Page 1260 Compression Check: Testing and Inspection INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. REMOVE SPARK PLUGS 5. CHECK CYLINDER COMPRESSION PRESSURE a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle c. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. d. Repeat steps a. through c. for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,230 kPa (12.5 kgf/cm2, 178 psi) or more Minimum pressure: 880 kPa (9.0 kgf/cm2, 127 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less e. If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps a. through c. for cylinders with low compression. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damage. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 6. REINSTALL SPARK PLUGS Torque: 19 Nm (200 kgf.cm, 14 ft. lbs.) 7. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 8. REINSTALL INTAKE AIR CONNECTOR Vehicle - Towing Guide. Towing Information: Technical Service Bulletins Vehicle - Towing Guide. BULLETIN NUMBER: AX001-00 DATE: March 17, 2000 TITLE: TOYOTA "DINGHY" TOWING GUIDE MODELS: All Models INTRODUCTION The chart on the next page indicates which Toyota vehicles can be Dinghy towed (towed with four wheels on the ground) behind a Motorhome CAUTION: Dinghy towing a vehicle behind a Motorhome requires special towing equipment and accessories. Please see your Motorhome Manufacturer/Service Outlet for recommended towing equipment. Warranty Information WARRANTY INFORMATION APPLICABLE VEHICLES Page 778 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2673 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2466 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2160 b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Torque: 5.4 Nm (55 kgf cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 849 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2468 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 722 Page 2959 Vehicle Speed Sensor NO.2 Page 71 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 338 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 3005 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 1680 Coolant: Service Precautions 1. Toyota Long Life Antifreeze Coolant is recommended by the manufacturer for maximum protection. 2. Mixing green and red colored coolants is not recommended. Page 1971 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2851 Engine Bank Identification Page 2857 Removal and Installation Radiator: Service and Repair Removal and Installation Page 293 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 733 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Page 2694 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2768 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2198 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 3274 Underdash Fuses And Relays Details Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Page 2067 Page 2773 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1355 Power Steering Fluid: Testing and Inspection INSPECTION 1. CHECK FLUID LEVEL a. Keep the vehicle level. b. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRON II or III HINT: Check that the fluid level is within the HOT LEVEL range on the reservoir cap dipstick. If the fluid is cold, check that it is within the COLD LEVEL range. c. Start the engine and run it at idle. d. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 8O°C (176°F) e. Check for foaming or emulsification. If there is foaming or emulsification, bleed power steering system. f. With the engine idling, measure the fluid level in the oil reservoir. g. Stop the engine. h. Wait a few minutes and remeasure the fluid level in the oil reservoir. Maximum fluid level rise: 5 mm (0.20 inch) If a problem is found, bleed power steering system. i. Check the fluid level. 2. CHECK STEERING FLUID PRESSURE a. 5VZ-FE Engine: Loosen the 3 bolts and air cleaner assembly. b. Disconnect the pressure feed tube from the PS vane pump. c. Connect SST, as shown below. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060) Page 708 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 158 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2358 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Locations Relay Box: Locations Underhood Fuses And Relays Testing and Inspection Door Switch: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY a. Check that continuity exists between terminal and the switch body in the ON position (switch pin released : opened door). b. Check that no continuity exists between terminal and the switch body in the OFF position (switch pin pushed in : closed door). If operation is not as specified, replace the switch Page 2367 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2270 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2283 How To Read Ground Points Page 2498 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1626 Idle Speed: Testing and Inspection INSPECTION 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected HINT: All vacuum hoses for EGR system, etc. should be properly connected. f. SFI system wiring connectors fully plugged g. Ignition timing check correctly h. Transmission in neutral position 2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL 3. INSPECT IDLE SPEED a. Race the engine speed at 2,500 rpm for approx. 90 seconds. b. Check the idle speed. Idle speed: 650 - 750 rpm If the idle speed is not as specified, check the IAC valve, intake air leakage and SFI system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL Page 2962 How To Read Ground Points Page 2437 Camshaft Position Sensor: Description and Operation The Camshaft position sensor (G signal) consists of a signal plate and pick up coil. The G signal plate has one tooth on its outer circumference and is mounted on the exhaust camshaft. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. Page 925 Front Page 2206 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 3384 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2109 Page 2288 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 764 Page 2724 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2221 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 3151 Mass Air Flow Meter: Description and Operation The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Page 24 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2242 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 41 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2392 Page 2947 Transmission Position Switch/Sensor: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch go on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay, thus the terminal NSW voltage becomes 0 V. When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM. Terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction and for idle speed control (estimated control), etc. The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in D position. When the shift position is except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. Page 2398 How To Read Ground Points Page 2153 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Testing and Inspection Drive Belt: Testing and Inspection 1. INSPECT DRIVE BELT'S INSTALLATION CONDITION Check that the drive belt fits properly in the ribbed grooves. 2. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt tension. Drive belt tension: New belt : 160 ± 25 lb Used belt : 100 ± 20 lb HINT: "New belt" refers to a belt which has been used less than 5 minutes on a running engine. - "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more. - After installing the drive belt, check that it fits properly in the ribbed grooves. Page 1728 Heater Core: Service and Repair REMOVAL 1. REMOVE HEATER UNIT 2. REMOVE HEATER RADIATOR a. Remove 3 screws and 3 plates and clamp. b. Pull the radiator upward. INSTALLATION Installation is in the reverse order of removal. Page 307 How To Read Ground Points Page 2239 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1599 11. REMOVE OIL PAN a. Remove the 16 bolts and 2 nuts. b. Insert the blade of Special Service Tool (SST) between the cylinder block and oil pan, cut off applied sealer and remove the oil pan. (SST) 09032-00100 NOTICE: Be careful not to damage the oil pan flanges of the oil pan and cylinder block. 12. REMOVE OIL STRAINER Remove the bolt, 2 nuts, oil strainer and gasket. 13. REMOVE CRANKSHAFT PULLEY a. w/ A/C: Remove the 4 bolts, No.2 and No.3 crankshaft pulleys. b. Using SST, remove the pulley bolt. SST 09213-54015, 09330-00021 c. Remove the crankshaft pulley. HINT: If necessary, remove the pulley with SST and crankshaft pulley bolt. SST 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09954-05020) 14. REMOVE TIMING CHAIN COVER Page 652 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 3095 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 871 Vapor Pressure Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1928 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 328 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 2774 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 798 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 210 Air Bag Control Module: Testing and Inspection 1. VEHICLE NOT INVOLVED IN COLLISION Do a diagnostic system check 2. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check 3. VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Replace the airbag sensor assembly Page 2262 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 3171 D. Start the engine. After the engine has stalled, turn the ignition switch OFF. E. Disable the fuel return line by blocking the line or installing the appropriate plug in the return outlet, if applicable. NOTE: Do NOT clamp plastic lines. F. Install the device adapter to the fuel line and then secure the swivel fitting on the end of the hose. G. Make sure the ball valve on the device is turned OFF (valve handle is crosswise to device). Screw the can of EFI cleaner (P/N 00289-1PF14) onto the device can adapter. H. Open the valve on the device, start the vehicle, and allow it to run until the engine stalls. I. Turn the ball valve OFF and remove the empty can. J. Place a shop towel over the can adapter and slowly open the ball valve to depressurize the system. K. Remove supply and return line adapters, reconnect vehicle fuel supply and return lines (replacing any fuel line gaskets and seals), and connect the fuel pump electrical connector. L. Before starting the vehicle, pressurize the fuel system and check for leaks. Run the engine for 4 - 5 minutes, and then snap the throttle several times to dislodge any carbon that may remain in the system. 2. Add 1 can of Toyota Non-Pressurized Fuel Injector Cleaner Fuel Tank Additive (P/N 08813-0080DS) to the fuel tank. 3. Road test the vehicle to verify normal operation. Page 2772 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Mechanical Specifications Power Steering Fluid: Mechanical Specifications Oil Level Rise: Maximum ............................................................................................................................................. ....................................... Below 5 mm (0.20 inch) Page 314 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 3139 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 38 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 426 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 791 How To Read Ground Points Page 3108 Vapor Pressure Sensor: Description and Operation CIRCUIT DESCRIPTION The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTC P0450 or P0451 is recorded by the ECM when the vapor pressure sensor malfunction. Page 1295 A/C Clamp Remover for removing special air condition line clamps. Applicable: 1998 and newer Toyota models with the new style A/C clamps. Comparable to Toyota Tool numbers 09870-00015 and 09870-00025. - Made in USA - Fits both Toyota AC Clamps, used on high and low pressure lines. - Applicable to: 1998 and newer Toyota models - Stainless Steel release pins - Identification and Instructions are laser marked on the handle Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 279 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Locations EFI Main Relay: Locations Underhood Fuses And Relays Page 895 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 164 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2390 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2407 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2985 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2223 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2555 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 3310 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch LOCK. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Locations Page 2457 Page 2989 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2007 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2633 CHART 7 Page 1265 a. Check only the valves indicated. - Using a thickness gauge, measure the clearance between the valve lifter and camshaft. - Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake: 0.15 - 0.25 mm (0.006 - 0.010 inch) Exhaust: 0.25 - 0.35 mm (0.010 - 0.014 inch) b. Turn the crankshaft pulley 1 revolution (360°) and align its groove with timing mark "O" of the timing chain cover. c. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 8. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. - Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. - Position the notch of the valve lifter toward the spark plug side. - Using Special Service Tool (SST) (A), press down the valve lifter and place (SST) (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) HINT: ^ Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration. Page 1855 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Diagram Information and Instructions Transmission Temperature Sensor/Switch: Diagram Information and Instructions O/D Cancel Signal Circuit Overdrive Switch: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D may be prohibited temporarily under some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 3174 Fuel Injector: Pressure, Vacuum and Temperature Specifications Pressure Drop Pressure Drop Resistance Per Injector 12-16 ohms Injection Volume 69-88 cm3 (4.2-5.4 cu in.) Per 15 seconds Difference Between Injectors 5 cm3 (0.3 cu in.) or less Leakage Rate Per Injector 1 drop or less per 3 Minutes Page 468 Step 2 Step 3 INSPECTION PROCEDURE Page 1776 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1102 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1952 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 968 Crankshaft Position Sensor: Testing and Inspection NOTE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10 ° C (14 ° F) to 50 °C (122 °F) and "Hot" is from 50 °C (122°F) to 100 °C (212 °F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (NE(+) and NE(-)): Cold: 1,630 - 2,740 Ohms Hot: 2,065 - 3,225 Ohms If the resistance is not as specified, replace the crankshaft position sensor. Page 645 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 1211 Alignment: Service and Repair NOTICE: - RZN161L: Tacoma Regular Cab 4WD 2.7L DOHC (3RZ-FE) - RZN171L: Tacoma Extra Cab 4WD 2.7L DOHC (3RZ-FE) - RZN191L: Tacoma Prerunner Reg Cab 2WD 2.7L (3RZ-FE) - RZN196L: Tacoma Prerunner Extra Cab 2WD 2.7L DOHC (3RZ-FE) - VZN170L: Tacoma Extra Cab 4WD 3.4L DOHC (5VZ-FE) - VZN195L: Tacoma Prerunner Extra Cab 2WD 3.4L DOHC (5VZ-FE) INSPECTION HINT: Pre runner is the model described below. 1. MEASURE VEHICLE HEIGHT Vehicle height: Measuring points: A: Ground clearance of spindle center. B: Ground clearance of front adjusting cam bolt center. C: Ground clearance of leaf spring front hanger pin bolt center. D: Ground clearance of rear axle shaft center. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to the specified value. If the vehicle height is not the specified value, try to adjust it by pushing down on or lifting the body. Page 1269 - Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 9. REINSTALL CYLINDER HEAD COVER 10. RECONNECT ENGINE WIRE 11. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 12. REINSTALL PCV HOSES 13. REINSTALL INTAKE AIR CONNECTOR Page 731 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ The fuel-cut is operated for 8 seconds or more (for Rear O2S Monitor). A. Allow the engine to idle for two minutes. B. Warm up the engine until the Engine Coolant Temperature (ECT) reaches 167°F (75°C). C. Drive the vehicle over 30 mph (48 km/h) for more than 40 seconds. D. Stop the vehicle and allow the engine to idle for more than 20 seconds. E. Repeat steps C and D at least 8 times in one driving cycle. (Do not cycle the ignition key.) In addition, perform the following steps for the Rear O2S Readiness Monitor: A. Select second gear. B. Allow the vehicle to run at 30 mph (48 km/h) or more. C. Keep the accelerator pedal "off-idle" for more than 10 seconds. D. Immediately after step C, release the accelerator pedal for at least 10 seconds without depressing the brake pedal (to execute the fuel-cut). E. Decelerate the vehicle until the vehicle speed reaches less than 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 3149 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2630 CHART 1 Page 2869 CHART 12 CHART 13 Page 813 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 779 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2408 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2045 CHART 2 CHART 3 CHART 4 Page 378 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Diagram Information and Instructions Vapor Pressure Sensor: Diagram Information and Instructions Page 2428 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 172 Part 2 Of 2 Page 627 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2243 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Testing and Inspection Oil Pressure Sender: Testing and Inspection INSPECT LOW OIL PRESSURE SWITCH a. Disconnect the connector from the switch. b. Check that continuity exists between terminal and ground with the engine stopped. c. Check that no continuity exists between terminal and ground with the engine running. HINT: Oil pressure should be over 49 kPa (0.5 kg/Sq.cm, 7.1 psi). If operation is not as specified, replace the switch. Page 2833 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2134 Transmission Position Switch/Sensor: Testing and Inspection Ford Made CIRCUIT DESCRIPTION When the shift position is put in positions except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM Step 1 Page 2037 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 2. Select the desired oxygen sensor and press Enter. NOTE: The monitor result of the A/F sensor will not be displayed. If you select "Bank 1-Sensor 1" or Bank 2-Sensor 1" for a vehicle equipped with an A/F sensor, the Diagnostic Tester will display "No parameter to display." 3. Compare the test results with the values listed in the Failure Threshold Chart. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," in this bulletin. 2. Select appropriate year, model, and engine for specified O2S Failure Threshold Chart. 3. Compare O2S test results with the specified O2S Failure Threshold Chart. It may be necessary to convert O2S test results to a specific measurement unit using the conversion factor that is supplied in the specified table. See example. Example: Page 2017 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1835 Applicable Warranty*: This repair is covered under the Federal Emissions Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in service date. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 1490 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE PCV HOSES 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. DISCONNECT ENGINE WIRE a. Disconnect these connectors: - w/ A/C: A/C compressor connector - Oil pressure sensor connector - Engine coolant temperature sender gauge connector - Ignition Coil connector b. Disconnect the 4 engine wire clamps and engine wire. 5. REMOVE CYLINDER HEAD COVER Remove the 10 bolts, seal washers, cylinder head cover and gasket. 6. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley clockwise and align its groove with the "0" mark on the timing chain cover. b. Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. 7. INSPECT VALVE CLEARANCE Page 2384 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2471 Starter Signal: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2033 Engine Bank Identification Page 2460 Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR a. Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 20 Nm (200 kg.cm, 14 ft.lb) b. Connect the ECT sensor connector. c. Install the engine wire protector to the 3 brackets. 5. REFILL ENGINE COOLANT Page 721 Applicable Vehicles Page 990 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 3326 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2127 Transmission Position Switch/Sensor: Electrical Diagrams Diagram Information and Instructions Mass Air Flow Meter: Diagram Information and Instructions Page 1991 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 87 Step 2 Step 3 INSPECTION PROCEDURE Page 460 Cruise Control Switch: Electrical Diagrams Page 2171 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2529 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 149 Underdash Fuses And Relays Details Page 3257 Page 547 Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Page 1782 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2807 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2895 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2748 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2458 Coolant Temperature Sensor/Switch (For Computer): Description and Operation A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the DTC P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). Page 2752 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2856 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Testing and Inspection Heater Control Valve: Testing and Inspection 1. WARM UP ENGINE 2. DISCONNECT WATER VALVE CONTROL CABLE 3. INSPECT WATER VALVE OPERATION a. Check that warm air blown out the vent when the water valve lever is moved to "WARM" position. b. Check that cool air blown out when the water valve is moved to the "COOL" position. If operation is not as specified, replace the water valve. 4. CONNECT WATER VALVE CONTROL CABLE After connection, adjust the control cable. Page 600 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 3253 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2068 CHART 27 Page 2222 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 416 How To Read Ground Points Page 2179 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2119 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Capacity Specifications Refrigerant Oil: Capacity Specifications When Replacing, Add: Receiver 20 cc Condenser 40 cc Evaporator 40 to 50 cc Page 3183 c. While turning the injector left and right, install it to the delivery pipe. Install the 4 injectors. d. Position the injector connector upward. 2. INSTALL INJECTORS AND DELIVERY PIPE a. Place the 4 new insulators and in position on the spacers. b. Place the 4 injectors together with the delivery pipe in position on the cylinder head. c. Temporarily install the 2 bolts holding the delivery pipe to the cylinder head. d. Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O-rings. Replace the O-rings. e. Position the injector connector upward. f. Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 21 Nm (210 kg.cm, 15 ft.lb) g. Connect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 29 Nm (300 kg.cm, 22 ft.lb) h. Connect the fuel return hose to the fuel pressure regulator. i. Connect the vacuum sensing hose to the fuel pressure regulator. 3. CONNECT ENGINE WIRE 4. INSTALL THROTTLE BODY Page 667 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1050 Step 4 O/D OFF indicator light does not light up Step 1 Step 2 Page 3225 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1717 Coolant Temperature Sensor/Switch (For Computer): Description and Operation A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the DTC P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). Page 1367 Refrigerant Oil: Fluid Type Specifications Type ND-OIL 8 Page 1030 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Page 748 CHART 15 Page 318 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2291 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 346 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1157 Page 1525 Drive Belt: Service and Repair REMOVAL 1. REMOVE PS PUMP DRIVE BELT 2. REMOVE ENGINE UNDER COVER 3. LOOSEN IDLE PULLEY LOCK NUT Torque: 39 Nm (400 kg.cm, 29 ft.lb) 4. REMOVE COMPRESSOR DRIVE BELT Loosen drive belt tension by adjusting bolt and remove the drive belt. INSTALLATION 1. TIGHTEN IDLE PULLEY LOCK NUT TEMPORALLY Torque: 2.5 Nm (25 kg.cm, 22 in.lb) 2. INSTALL DRIVE BELT 3. USING ADJUSTING BOLT, ADJUST DRIVE BELT TENSION Drive belt tension New belt: 160 ± 25 lb Used belt: 100 ± 25 lb 4. TIGHTEN IDLE PULLEY LOCK NUT Torque: 39 Nm (400 kg.cm, 29 ft.lb) 5. INSTALL PS PUMP DRIVE BELT 6. INSTALL ENGINE UNDER COVER Page 1961 Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR a. Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 20 Nm (200 kg.cm, 14 ft.lb) b. Connect the ECT sensor connector. c. Install the engine wire protector to the 3 brackets. 5. REFILL ENGINE COOLANT Page 548 Testing and Inspection Hazard Warning Switch: Testing and Inspection Reference INSPECT HAZARD WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1347 w/ Oil filter change: 5.4 liters (5.7 U S qts., 4.8 Imp. qts.) w/o Oil filter change: 4.7 liters (5.0 US qts., 4.1 Imp. qts.) Reinstall the oil filler cap. 4. START ENGINE AND CHECK FOR LEAKS 5. RECHECK ENGINE OIL LEVEL Page 459 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 1593 TIMING CHAIN AND RELATED COMPONENTS Page 873 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1134 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 906 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. Page 379 Page 2638 CHART 14 Page 2489 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1966 How To Read Ground Points Page 648 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2810 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2357 How To Read Ground Points Page 2972 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2813 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Service and Repair Piston Pin: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 2209 Mass Air Flow Meter: Description and Operation The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the mass air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of A and B remains equal to maintain the set temperature. Page 2038 A. The Diagnostic Tester displays 17" as a value of the Time $81" (see illustration). B. Find the Conversion Factor value of Time $81" in the O2S Failure Threshold chart. 0.3906 is specified for Time $81 in this chart. C. Multiply "17" in step "A" by 0.3906 (Conversion Factor) in step "B." 17 x 0.3906 = 6.6% D. If the answer is within the Standard Value of TEST LIMIT, the Time $81" can be confirmed to be normal. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. NOTE: Before the O2S Monitor completes or after the ignition switch is turned OFF, the Diagnostic Tester displays the viewable upper limit or a lower limit of the test value (example: 0 V, 1.275 V, Os [seconds], 10.2s, 0 and 255). Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Page 1040 Overdrive Switch: Electrical Diagrams Page 3256 Page 2104 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3297 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1063 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Specifications Air Bag Control Module: Specifications Air Bag Sensor Assembly Replacemement Air Bag Sensor Assembly Replacemement Air Bag Sensor Assembly Mounting Bolts 20 Nm Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Page 2098 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2619 Engine Bank Identification Page 1478 Piston: Service and Repair For information regarding the Service and Repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 34 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 822 Transmission Position Switch/Sensor: Electrical Diagrams Page 2819 Intake Air Temperature Sensor: Description and Operation The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. Figure 1 The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value. The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temp. sensor are connected in series. When the resistance value of the intake air temp. sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 631 Page 2481 Step 1 Step 2 TOYOTA hand-held tester Page 1210 Alignment: Specifications Vehicle Height: Front* ................................................................................................................................................... ................................................ 48 mm (1.89 inch) Rear** ................................................................... ............................................................................................................................... 48 mm (1.89 inch) Camber ................................................................................................................................................ ........................................... 0°18' ± 45' (0.3° ± 0.75°) Right-Left Error .................................................................................................................................... ................................................. 30' (0.5°) Or Less Caster .................................................................................................................................................. ........................................... 1°30' ± 45' (1.5° ± 0.75°) Right-Left Error .................................................................................................................................... ................................................. 30' (0.5°) Or Less Steering Axis Inclination ............................................................................................................................................................ 10°30' ± 45' (10.5° ± 0.75°) Right-Left Error .................................................................................................................................... ................................................. 30' (0.5°) Or Less Toe In: Total .............................................................................................................................................. 0°12' ± 12' (0.2° ± 0.2°), 2 ± 2 mm (0.08 ± 0.08 inch) Rack End Length Difference .......................................................................................................................................... 1.5 mm (0.059 inch) Or Less Wheel Angle: Maximum: Inside Wheel .................................................................................................................................. 37°05' (35°05' - 38°05'), 37.08° (35.08° - 38.08°) Outside Wheel ....................................................... .............................................................................................................................. 32°20' (32.33°) *A-B A: Ground Clearance Of Spindle Center. B: Ground Clearance Of Lower Suspension Arm Bolt Center. ** C - D C: Ground Clearance Of Rear Axle Shaft Center. D: Ground Clearance Of Leaf Spring Front Hanger Pin Center. Page 3061 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1907 Mass Air Flow Meter: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1029 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1860 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2046 CHART 5 CHART 6 Page 1326 Fluid - M/T: Fluid Type Specifications M/T Fluid Grade ................................................................................................................................................... ..................................................... API GL-4 or GL-5 Viscosity .............................................................................................................................................. .............................................................. SAE 75W-90 Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Testing and Inspection Power Window Switch: Testing and Inspection INSPECT POWER WINDOW MASTER SWITCH CONTINUITY Driver's switch(Window unlock) Driver's switch(Window lock) Passenger's switch(Window unlock) Passenger's switch(Window lock) If continuity is not as specified, replace the switch. INSPECT POWER WINDOW SWITCH CONTINUITY If continuity is not as specified, replace the switch. Using an ammeter: Page 2696 Page 3266 Idle Air Control Valve: Service and Repair COMPONENTS REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket. INSTALLATION 1. INSTALL IAC VALVE Page 48 Electronic Brake Control Module: Testing and Inspection Page 3179 g. Install the O-ring to the injector. h. Connect SST (union and hose) to the injector and hold the injector and union with SST (clamp). SST 09268-41047 i. Put the injector into a graduated cylinder. HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. j. Connect the TOYOTA hand-held tester to the DLC3. k. Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842-30070 Volume: 69 - 88 cu.cm (4.2 - 5.4 cu.in.) per 15 seconds Difference between each injector: 5 cu.cm (0.3 cu.in.) or less If the injection volume is not as specified, replace the injector. 2. INSPECT LEAKAGE a. In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842-30070 Fuel drop: 1 drop or less per 3 minutes b. Turn the ignition switch to LOCK. c. Disconnect the negative (-) terminal cable from the battery. d. Remove the SST and TOYOTA hand-held tester. SST 09268-41045 e. Reinstall the fuel pressure regulator and fuel inlet pipe. Page 2183 Denso Made Transmission Position Switch/Sensor: Testing and Inspection Denso Made CIRCUIT DESCRIPTION When the shift position is put in positions except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM Step 1 Exhaust System - Manifold Heat Shield Rattle Noise Heat Shield: All Technical Service Bulletins Exhaust System - Manifold Heat Shield Rattle Noise Engine EG004-00 June 2, 2000 Title: EXHAUST MANIFOLD HEAT SHIELD RATTLE NOISE Models: '95 - '00 Tacoma Introduction Some Tacoma vehicles may experience a rattle noise caused by the exhaust manifold heat shield. Two wire mesh grommets and a reinforcement patch on the underside have been added to reduce the possibility of the exhaust manifold heat shield rattle noise. Applicable Vehicles ^ 1995 - 2000 model year Tacoma vehicles (except CA Spec.) equipped with 2RZ-FE or 3RZ-FE engines produced before the VINs listed. Production Change Information Parts Information Repair Procedure 1. Inspect the Exhaust Manifold Heat Shield for cracking around the 2 bolts and 2 studs. 2. If cracking is found, replace the Exhaust Manifold Heat Shield, Bolts, Washers, Studs, and Nuts in specified quantities. 3. Insert 2 bolts. (P/N 90110-06894) 4. Reuse studs/nuts in the specified areas. Warranty Information Page 1559 Intake Manifold: Specifications Throttle Body Fasteners 20 Nm (14 ft.lb) Page 2518 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 832 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES. 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH. Torque: Nut: 6.9 Nm (70 kgf cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR CONNECT 2 OIL COOLER PIPES Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 298 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3287 Locations Page 623 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 3207 Fuel Supply Line: Testing and Inspection COMPONENTS CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. INSPECTION INSPECT FUEL TANK AND LINE Page 2533 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1764 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A" and "B" are not deformed, cracked, or swollen. 3. Check that points "B" and "C" are not stuck together. 4. Apply engine coolant to point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Page 603 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 3311 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. Page 1034 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1876 Locations Page 876 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Page 2085 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2785 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 3252 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 296 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Page 641 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2652 CHART 26 Page 2482 Step 1 Step 2 OBD II scan tool (excluding TOYOTA hand-held tester) Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Page 1913 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Specifications Connecting Rod Bearing: Specifications Connecting Rod Clearance: Oil: Standard ................................................................................................................................................ 0.030 0.055 mm (0.0012 - 0.0022 inch) U/S 0.25 ................................................................................................................................................ 0.031 0.071 mm (0.0012 - 0.0026 inch) Maximum ........................................................................................ ................................................................................... 0.10 mm (0.0039 inch) Thrust: Standard ................................................................................................................................................ 0.160 0.312 mm (0.0063 - 0.0123 inch) Maximum ........................................................................................ ................................................................................... 0.35 mm (0.0138 inch) Page 988 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Locations Fusible Link: Locations Underhood Fuses And Relays Page 1989 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3324 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Page 1604 3. 2RZ-FE: INSPECT OIL JET Check the oil for damage or clogging. If necessary, replace the oil jet. 4. INSPECT NO.1 CHAIN TENSIONER 5. 3RZ-FE: INSPECT NO.2 CHAIN TENSIONER a. Inspect the chain tensioner - Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. - Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger. b. Inspect the oil jet (No.2 chain tensioner). Check the oil jet for damage or clogging. If necessary, replace the oil jet (No.2 chain tensioner). INSTALLATION Page 2812 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 810 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 3010 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2651 Page 1332 Fluid - Differential: Fluid Type Specifications Front Differential With Automatic Disconnecting Differential (A.D.D.): Hypoid Gear Oil API GL-5 ................................. ............................................................................................................................................. SAE 75W-90 Less A.D.D: Hypoid Gear Oil API GL-5 Above -18°C (0°F) ................................................... .................................................................................................................................................. SAE 90 Below -18°C (0°F) .......................................................................................................................... .................................................... SAE 80W Or 80W-90 Rear Differential DIFFERENTIAL OIL API GL - 5 Hypoid Gear Oil: Above - 18° C (0° F) ............................................. ................................................................................................................................................. SAE 90W Below - 18° C (0° F) .................................................................................................................... ...................................................... SAE 80W - 90 or 80W ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 3046 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 1. DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. Page 2666 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 987 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1155 Testing and Inspection Hose/Line HVAC: Testing and Inspection 1. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. Page 2248 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 694 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2952 Transmission Position Switch/Sensor: Testing and Inspection Ford Made CIRCUIT DESCRIPTION When the shift position is put in positions except D, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. WIRING DIAGRAM Step 1 Page 1198 d. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2, check that the meter needle indicates battery positive voltage. If operation is not as specified, replace the wiper and washer switch. INSPECT REAR WIPER AND WASHER SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT WASHER LINKED OPERATION a. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. b. Connect the positive (+) lead from the voltmeter to terminal 7 and the negative (-) lead to terminal 2. Page 2071 CHART 29 Page 608 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 1446 Camshaft Gear/Sprocket: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 628 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2061 CHART 23 Page 1137 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2883 Page 2534 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1733 W/O Tachometer HINT: Connect the test leads so that the current from the ohmmeter can flow according to the above order. This circuit includes the diode. If resistance value is not as specified, replace the receiver gauge. Page 1936 Page 1062 Throttle Position Sensor/Switch: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Diagnostic Trouble Code Tests and Associated Procedures Idle Air Control Valve: Diagnostic Trouble Code Tests and Associated Procedures CIRCUIT DESCRIPTION The rotary solenoid type IAC valve is located in front of the intake air chamber and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle-up and provide feedback for the target idling speed. DETECTING CONDITIONS WIRING DIAGRAM Page 2655 Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Page 2944 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2612 Applicable Vehicles Page 3228 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1950 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2789 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 452 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Diagram Information and Instructions Starter Signal: Diagram Information and Instructions Page 850 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2874 CHART 20 Page 2244 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1104 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1742 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 3218 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2767 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 78 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Specifications Compression Check: Specifications Compression Pressure 1230 kPa (178 psi) or more Minimum Pressure 880 kPa (127 psi) Difference Between Each Cylinder 98 kPa (14 psi) or less Page 534 Part 1 Of 4 Page 2966 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Specifications Crankshaft Main Bearing: Specifications Main Bearing Oil Clearance Standard Clearance No.3 - Std. 0.030-0.055 mm Others - Std. 0.024-0.049 mm No.3 - U/S 0.25 0.030-0.070 mm Others - U/S 0.25 0.025-0.065 mm Maximum Clearance 0.10 mm Bearing Center Wall Thickness Std. Mark "1" 1.987-1.990 mm Std. Mark "2" 1.991-1.993 mm Std. Mark "3" 1.994-1.996 mm U/S 0.25 2.106-2.112 mm Main Bearing Cap Bolts Step 1 39 Nm (29 ft.lb) Step 2 Turn 90 degrees Page 1775 How To Read Ground Points Page 3353 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 736 Page 740 CHART 2 CHART 3 CHART 4 Page 940 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2059 CHART 22 Page 3013 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 688 Intake Air Temperature Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Page 2986 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 376 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1292 Hose/Line HVAC: Service and Repair LOCATION 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 2. REPLACE FAULTY TUBE OR HOSE NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. 3. TIGHTEN JOINT OF BOLT OR NUT AT SPECIFIED TORQUE NOTE: Connections should not be torqued tighter than the specified torque. 4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. Page 1953 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 841 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Diagrams Page 2607 EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION a. Apply battery positive voltage across terminals 86 and 85. b. Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Page 2951 Step 4 INSPECTION PROCEDURE Page 860 Exhaust Gas Recirculation Gas Temperature Sensor: Testing and Inspection COMPONENTS INSPECTION 1. REMOVE EGR VALVE 2. REMOVE EGR GAS TEMPERATURE SENSOR 3. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 64 - 97 kohms at 50 °C (122 °F) 11 - 16 kohms at 100 °C (212 °F) 2 - 4 kohms at 150 °C (302 °F) If the resistance is not as specified, replace the sensor. 4. REINSTALL EGR GAS TEMPERATURE SENSOR 5. REINSTALL EGR VALVE Page 2165 Exhaust Gas Recirculation Gas Temperature Sensor: Testing and Inspection COMPONENTS INSPECTION 1. REMOVE EGR VALVE 2. REMOVE EGR GAS TEMPERATURE SENSOR 3. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 64 - 97 kohms at 50 °C (122 °F) 11 - 16 kohms at 100 °C (212 °F) 2 - 4 kohms at 150 °C (302 °F) If the resistance is not as specified, replace the sensor. 4. REINSTALL EGR GAS TEMPERATURE SENSOR 5. REINSTALL EGR VALVE Page 1127 b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Torque: 5.4 Nm (55 kgf cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Locations Diagrams Page 399 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 437 Step 1 Step 2 Page 28 Brake Fluid Solenoid Valve Relay: Description and Operation ABS Actuator Solenoid This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, it the initial check is OK, the relay goes on. ABS Solenoid Valve This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders thus controlling the braking force. Testing and Inspection Temperature Gauge: Testing and Inspection INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE OPERATION a. Disconnect the connector from the sender gauge. b. Turn the ignition switch ON and check that the receiver gauge needle indicates COOL. c. Ground terminal on the wire harness side connector through a 3.4 W test bulb. d. Turn the ignition switch ON, and check that the bulb lights up and the receiver gauge needle moves to the hot side. If operation is as specified, replace the sender gauge. Then, recheck the system. If operation is not as specified, measure the receiver gauge resistance. INSPECT ENGINE COOLANT TEMPERATURE RECEIVER GAUGE RESISTANCE Measure the resistance between terminals. W/ Tachometer Page 687 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2240 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 1968 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3140 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2454 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Testing and Inspection Drive Belt: Testing and Inspection 1. INSPECT DRIVE BELT'S INSTALLATION CONDITION Check that the drive belt fits properly in the ribbed grooves. 2. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt tension. Drive belt tension: New belt : 160 ± 25 lb Used belt : 100 ± 20 lb HINT: "New belt" refers to a belt which has been used less than 5 minutes on a running engine. - "Used belt" refers to a belt which has been used on a running engine for 5 minutes or more. - After installing the drive belt, check that it fits properly in the ribbed grooves. Front Axle Nut: Specifications Front Drive Shaft Lock Nut 235 Nm (174 ft.lb) Page 3031 How To Read Ground Points Page 410 Step 2 Step 3 Page 948 Camshaft Position Sensor: Service and Repair COMPONENTS REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. b. Remove the bolts and camshaft position sensor. Torque: 5.4 Nm (55 kg.cm, 48 in.lb) INSTALLATION Installation is in the reverse order of removal. Page 2793 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1994 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 3337 Throttle Body: Testing and Inspection Component Inspection 1. CLEAN THROTTLE BODY a. Using a soft brush and carburetor cleaner, clean the cast parts. b. Using compressed air, clean all the passages and apertures. NOTE: To prevent deterioration, do not clean the throttle position sensor and IAC valve. 2. INSPECT THROTTLE VALVE a. Apply vacuum to the throttle opener. b. Check that there is no clearance between the throttle stop screw and throttle lever when the throttle valve is fully closed. 3. INSPECT THROTTLE POSITION SENSOR a. Apply vacuum to the throttle opener. b. Insert a thickness gauge between the throttle stop screw and stop lever. Page 1485 Piston Ring: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Locations Page 2557 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1955 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1236 Fuel Pressure Release: Service and Repair GENERAL PRECAUTIONS 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal removed from The battery. Therefore, if necessary, read the diagnostic trouble code(s) before removing the negative (-) terminal cable from the battery. 2. Do not smoke or work near an open flame when working on the fuel system. FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH PRESSURE FUEL LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: - Put a container under the connection. - Slowly loosen the connection. - Disconnect the connection. - Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use a new gasket. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare and tighten the flare nut by hand. - Using SST, tighten the flare nut to the specified torque. SST 09631-22020 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Diagram Information and Instructions Wheel Speed Sensor: Diagram Information and Instructions Page 2210 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch LOCK. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Page 2150 Vehicle Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 599 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1126 Transmission Speed Sensor: Service and Repair ON-VEHICLE REPAIR Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 1. DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR Vehicle Speed Sensor NO.2 Vehicle Speed Sensor NO.2 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. Page 729 A/F and 02 Sensor Identification Standard Value of ECM Terminals Engine Control Module: Testing and Inspection Standard Value of ECM Terminals Part 1 Of 2 Page 2135 Step 2 Step 3 Page 3106 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2298 Knock Sensor: Testing and Inspection 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR a. Disconnect the knock sensor connector. b. Using SST remove the knock sensor. SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Using SST, install the knock sensor. SST 09816-30010 Torque: 44 Nm (450 kg.cm, 33 ft.lb) b. Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 Nm (200 kg.cm, 14 ft.lb) 7. REINSTALL STARTER Page 1346 Engine Oil: Service and Repair REPLACEMENT CAUTION: Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer. - Care should be taken, therefore, when changing engine, oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves that cannot be penetrated by oil should be worn. The skin should be thoroughly washed with soap and water, or use water-less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. - In order to preserve the environment, used oil and used oil filters must be disposed of only at designated disposal sites. 1. DRAIN ENGINE OIL a. Remove the oil filler cap. b. Remove the oil drain plug, and drain the oil into a container. 2. REPLACE OIL FILTER a. Using Special Service Tool (SST), remove the oil filter. (SST) 09228-07501 b. Check and clean the oil filter installation surface. c. Apply clean engine oil to the gasket of a new oil filter. d. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. e. Using SST, tighten it an additional 3/4 turn. SST 09228-07501 3. REFILL WITH ENGINE OIL a. Clean and install the oil drain plug with a new gasket. Torque: 37 Nm (375 kgf.cm, 27 ft. lbs.) b. Fill with fresh engine oil. Oil capacity 2WD: Dry fill: 6.2 liters (6.6 US qts., 5.5 Imp. qts.) Drain and refill w/ Oil filter change: 5.5 liters (5.8 US qts., 4.8 Imp. qts.) w/o Oil filter change: 4.8 liters (5.0 US qts., 4.2 Imp. qts.) 4WD: Dry fill: 5.8 liters (6.1 US qts., 5.1 Imp. qts.) Drain and refill Page 350 Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Page 420 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 546 I15-A SEAT BELT WARNING RELAY (INTEGRATION RELAY) 6-GROUND : Approx. 12 Volts with Ignition SW ON 12-GROUND : Always Approx. 12 Volts A-7-GROUND: Always Continuity A-5-GROUND: Continuity with LH Door open A-10-GROUND : Approx. 12 Volts with Ignition Key in Cylinder A-2-GROUND: 0 Volts for 4-8 Seconds with Ignition SW ON and 12 Volts 4-8 Seconds after Ignition SW ON Splice Points System Outline Current always flows to TERMINAL 12 of the integration relay through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the Ignition SW is turned ON, current flows from the GAUGE fuse to TERMINAL 6 of the integration relay. At the same time, current flows to TERMINAL (A) 2 of the relay from the GAUGE fuse through the Seat Belt Warning Light. This current activates the integration relay and, for Approx. 4-8 Seconds, current flowing through the warning light flows from TERMINAL (A) 2 of relay to TERMINAL (A) 7 to GROUND, causing the warning Light to Light up. At the same time as the warning Light Lights up, a buckle SW ON signal is input to TERMINAL (A) 3 of the integration relay, the current flowing from TERMINAL 12 of the relay flows to TERMINAL (A) 7 to GROUND and the Seat Belt Warning Buzzer Sounds for Approx. 4-8 Seconds. However, if the Seat Belt is put ON (Buckle SW OFF) during this period (While The Buzzer is Sounding), signal input to TERMINAL (A) 3 of the integration relay Stops and the current flowing from TERMINAL 12 of the integration relay to TERMINAL (A) 7 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the Ignition Key inserted in the key Cylinder (Unlock warning SW ON), the Ignition SW still OFF and front LH door open (Door Courtesy SW ON), when a signal is input to TERMINAL (A) 10 of the integration relay, the Integration Relay operates, current flows from TERMINAL 6 of the relay to TERMINAL (A) 7 to GROUND and the Key Reminder Buzzer sounds. Parts Location Page 931 How To Read Ground Points Page 2632 CHART 5 CHART 6 Page 1916 Mass Air Flow Meter: Testing and Inspection 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION a. Connect the negative (-) terminal cable to the battery. b. Turn the ignition switch ON. c. Connect the MAF meter connector. d. Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (-) tester probe to terminal E3. e. Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. f. Turn the ignition switch LOCK. g. Disconnect the negative (-) terminal cable from the battery. h. Disconnect the MAF meter connector. Page 16 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3258 Idle Air Control Valve: Description and Operation The rotary solenoid type IAC valve is located on the throttle body and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throttle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle-up and provide feedback for the target idling speed. Page 2990 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1500 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Page 2382 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 64 After replacing the cruise control ECU, perform the cable adjustment procedure as necessary. 1. Confirm cable free play: A. Eliminate slack of inner cable by pushing the inner cable toward the actuator until it stops. While the cable is held, mark the position of the cable by using tape. B. Pull the inner cable toward the throttle cam and measure the clearance between the mark and the outer cable tip. 2. Adjust the cable free play: A. Loosen lock nut of throttle cam side and adjust the clearance to 1 or 2 mm. B. Tighten lock nut of actuator side. Torque: 12 N-m/8 ft-lbs C. Confirm clearance of 1 to 2 mm. Specifications Engine Oil Pressure: Specifications Oil Pressure at Idle 29 kPa (4.3 psi) or more Oil Pressure at 3000 rpm 245-490 kPa (36-71 psi) Page 1777 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1906 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 225 Starter Relay: Testing and Inspection 1. REMOVE STARTER RELAY LOCATION: The relay is located in the junction block on the driver's side. 2. INSPECT STARTER RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. 3. INSPECT STARTER RELAY OPERATION a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 4. REINSTALL STARTER RELAY Page 1768 Radiator Cap: Testing and Inspection 1. REMOVE RADIATOR CAP CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. 2. INSPECT RADIATOR CAP NOTICE: If the radiator cap has contaminations, always rinse it with water. Using a radiator cap tester, pump the tester and measure the vacuum valve opening pressure. Standard opening pressure: 74 - 103 kPa (10.7 - 14.9 psi) Minimum opening pressure: 59 kPa (8.5 psi) HINT: Use the tester's maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the radiator cap. 3. REINSTALL RADIATOR CAP Page 1248 Ignition Cable: Testing and Inspection INSPECT HIGH-TENSION CORDS a. Remove the air cleaner cap and MAF meter assembly. b. Remove the intake air connector. c. Disconnect the high-tension cords from the spark plugs. NOTE: Pulling on or bending the cords may damage the conductor inside. d. Disconnect the high-tension cords from the ignition coils. 1. Using a screwdriver, lift up the lock claw and disconnect the holder from the ignition coils. 2. Disconnect the high-tension cord at the grommet. NOTE: Pulling on or bending the cords may damage the conductor inside. - Do not wipe any of the oil from the grommet after the high- tension cord is disconnected. e. Using an ohmmeter, measure the resistance. Maximum resistance: 25 kohms per cord Page 3068 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1047 Overdrive Switch: Testing and Inspection O/D Main Switch & O/D Off Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. In O/D main switch at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting O/D. WIRING DIAGRAM INSPECTION PROCEDURE Page 643 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 179 Step 6 Step 7 INSPECTION PROCEDURE Page 1561 Intake Manifold: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair; Removal and Installation. Page 1909 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2412 Brake Signal: Description and Operation Stop Light Switch Signal Engine This signal is used to detect when the brakes have been applied. The STP signal voltage is the same as the voltage supplied to the stop lights. The STP signal is used mainly to control the fuel cut-off engine speed (The fuel cut-off engine speed is reduced slightly when the vehicle is braking.). Automatic Transaxle The purpose of this circuit is to prevent the engine from stalling, while driving in lock-up condition, when brakes are suddenly applied. When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Page 2304 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 138 Underdash Fuses And Relays Details Page 1176 Service Hints P 1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW] 1-2: Closed with A/T shift lever at P position D 4 DETECTION SW [TRANSFER NEUTRAL POSITION] 1-2: Closed with transfer position at N position Splice Points Page 2476 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 842 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 653 Page 2631 CHART 2 CHART 3 CHART 4 Page 2360 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1903 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1352 Power Steering Fluid: Capacity Specifications Power Steering Fluid: Total ..................................................................................................................................................... .......................................... 0.8 liters (0.9 US Qts.) Replacement Requirements Air Bag Control Module: Service and Repair Replacement Requirements REPLACEMENT REQUIREMENTS In the following cases, replace the airbag sensor assembly. - If the SRS has been deployed in a collision. - If the airbag sensor assembly has been found to be faulty in troubleshooting. - If the airbag sensor assembly has been dropped. CAUTION: For removal and installation of the airbag sensor assembly, be sure to follow the correct procedure. Page 2564 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1594 Timing Chain: Service and Repair Page 2451 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 754 CHART 22 Page 3348 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Specifications Brake Fluid: Specifications Fluid Type FMVSS 116 DOT 3 Brake Fluid Page 2124 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Specifications Water Pump: Specifications Water Pump Bolts 14 mm head bolt 24.5 Nm (18 ft.lb) 12 mm head bolt 8.9 Nm (78 in.lb) Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Page 3233 Part 4 Of 4 Page 481 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2013 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1065 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2453 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2501 Crankshaft Position Sensor: Description and Operation Crankshaft position sensor (NE signal) consists of a signal plate and pickup coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals, and the actual crankshaft angle and the engine speed by the NE signals. Page 3359 Page 3065 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2683 How To Read Ground Points Page 1457 Connecting Rod Bearing: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 1691 Applicable Warranty*: This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 2228 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2702 Part 2 Of 2 Page 2574 Step 6 INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand-held tester or OBD II scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air-fuel ratio lean or rich, etc. at the time of the malfunction. Page 3381 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2264 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1712 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2208 Page 744 CHART 10 Capacity Specifications Fluid - Transfer Case: Capacity Specifications Transfer Case Capacity ............................................................................................................................................... ............................................................. 1.0L (1.1 Qt) Page 2472 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1438 Compression Check: Testing and Inspection INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. REMOVE SPARK PLUGS 5. CHECK CYLINDER COMPRESSION PRESSURE a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle c. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. d. Repeat steps a. through c. for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,230 kPa (12.5 kgf/cm2, 178 psi) or more Minimum pressure: 880 kPa (9.0 kgf/cm2, 127 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less e. If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps a. through c. for cylinders with low compression. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damage. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 6. REINSTALL SPARK PLUGS Torque: 19 Nm (200 kgf.cm, 14 ft. lbs.) 7. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 8. REINSTALL INTAKE AIR CONNECTOR Page 341 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2955 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1. DISCONNECT 2 OIL COOLER PIPES. 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 3. REMOVE PARK/NEUTRAL POSITION SWITCH a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH. Torque: Nut: 6.9 Nm (70 kgf cm, 61 inch lbs.) Bolt: 13 Nm (130 kgf cm, 9 ft. lbs.) 5. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR CONNECT 2 OIL COOLER PIPES Page 2576 b. Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 c. After engine speed is kept at approx. 1,000 - 1500 rpm for 5 seconds, check that it returns to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. d. Remove the SST. SST 09843-18020 Page 2787 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Capacity Specifications Coolant: Capacity Specifications With M/T 8.3 L (8.8 US qts.) With A/T 8.2 L (8.7 US qts.) Page 2245 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 3382 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2896 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 44 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 231 Underdash Fuses And Relays Details Page 1882 Fuel Pump Relay: Testing and Inspection COMPONENTS INSPECTION 1. REMOVE LOWER FINISH NO.1 PANEL 2. REMOVE CIRCUIT OPENING RELAY 3. INSPECT CIRCUIT OPENING RELAY CONTINUITY a. Using and ohmmeter, check that there is continuity between terminals STA and E1. If there is no continuity, replace the relay. b. Check that there is continuity between terminals +B and FC. If there is no continuity, replace the relay. c. Check that there is no continuity between terminals +B and FP. If there is continuity, replace the relay. 4. INSPECT CIRCUIT OPENING RELAY OPERATION Page 686 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Electrical Specifications Fuel Injector: Electrical Specifications Resistance Resistance Resistance Between Terminals 12 to 16 ohms at 68 deg F Page 1254 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 20 Nm Page 2827 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 758 CHART 24 Page 2346 a. Check only the valves indicated. - Using a thickness gauge, measure the clearance between the valve lifter and camshaft. - Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake: 0.15 - 0.25 mm (0.006 - 0.010 inch) Exhaust: 0.25 - 0.35 mm (0.010 - 0.014 inch) b. Turn the crankshaft pulley 1 revolution (360°) and align its groove with timing mark "O" of the timing chain cover. c. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 8. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. - Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. - Position the notch of the valve lifter toward the spark plug side. - Using Special Service Tool (SST) (A), press down the valve lifter and place (SST) (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) HINT: ^ Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration. Page 18 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 827 Step 2 Step 3 Page 3096 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 418 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 224 Locations Page 191 Fuel Pump Relay: Testing and Inspection COMPONENTS INSPECTION 1. REMOVE LOWER FINISH NO.1 PANEL 2. REMOVE CIRCUIT OPENING RELAY 3. INSPECT CIRCUIT OPENING RELAY CONTINUITY a. Using and ohmmeter, check that there is continuity between terminals STA and E1. If there is no continuity, replace the relay. b. Check that there is continuity between terminals +B and FC. If there is no continuity, replace the relay. c. Check that there is no continuity between terminals +B and FP. If there is continuity, replace the relay. 4. INSPECT CIRCUIT OPENING RELAY OPERATION Page 742 CHART 7 Page 2697 Engine Control Module: Connector Views Part 1 Of 2 Page 2054 CHART 16 CHART 17 Page 198 EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION a. Apply battery positive voltage across terminals 86 and 85. b. Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Page 102 Control Module HVAC: Service and Repair REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE AMPLIFIER a. Disconnect the connector from the amplifier. b. Remove amplifier cover. c. Remove the amplifier from the cooling unit. INSTALLATION Installation is in the reverse order of removal. Page 2765 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2041 Page 2217 How To Read Ground Points Page 2330 If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. f. Connect the high-tension cords to the ignition coils. 1. Assemble the holder and grommet. 2. Align the spline of the ignition coil with the spline of the holder, and push in the cord. NOTE: Check that the holder is correctly installed to the grommet and ignition coil as shown in the illustration. 3. Check that the lock claw of the holder is engaged by lightly pulling the holder. g. Connect the high-tension cords to the spark plugs. Secure the high-tension cords with the clamps as shown in the illustration. h. Install the intake air connector. i. Install the air cleaner cap and MAF meter assembly. Page 1603 c. Using vernier calipers, measure the timing gear and timing sprocket diameter with the chain. NOTICE: Vernier calipers must contact the chain rollers for measuring. Minimum gear diameter (w/ chain): Camshaft: 113.8 mm (4.480 inch) Crankshaft: 59.4 mm (2.339 inch) 3RZ-FE: Balance shaft: 75.9 mm (2.988 inch) Minimum sprocket diameter (w/ chain): 3RZ-FE: No.2 crankshaft: 96.7 mm (3.807 inch) If the diameter is less than minimum, replace the chain, gears and sprocket. 2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRATION DAMPERS Measure the chain tensioner slipper and vibration damper wears. Maximum wear: 1.0 mm (0.039 inch) If the wear is greater than maximum, replace the slipper and/or dampers. Page 1167 Junction Block and Wire Harness Connector Page 1809 6. w/PS: REMOVE DRIVE BELT FOR PS PUMP Loosen the lock bolt and adjusting bolt, and remove the drive belt. 7. REMOVE FAN SHROUDS a. Remove the 2 clips and No.2 fan shroud. b. Remove the 4 bolts and No.1 fan shroud. 8. w/ A/C: REMOVE DRIVE BELT FOR A/C COMPRESSOR Loosen the idler pulley nut and adjusting bolt, and remove the drive belt. 9. REMOVE DRIVE BELT FOR GENERATOR, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY a. Stretch the belt and loosen the water pump pulley nuts. b. Loosen the lock, pivot and adjusting bolts of the generator, and remove the drive belt. c. Remove the 4 water pump pulley nuts. Torque: 21 Nm (210 kgf.cm, 16 ft. lbs.) d. Pull out the fan together with the fluid coupling and water pump pulley. 10. REMOVE WATER PUMP Remove the 10 bolts, water pump and gasket. Torque: 14 mm head bolt: 24.5 Nm (250 kgf.cm, 18 ft. lbs.) 12 mm head bolt: 8.9 Nm (90 kgf.cm, 78 inch lbs.) HINT: At the time of installation, please refer to the following items. Use a new gasket. Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 3347 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1787 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2935 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1505 Valve Cover: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 3295 How To Read Ground Points Page 2430 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3281 Fuel Pump Relay: Testing and Inspection COMPONENTS INSPECTION 1. REMOVE LOWER FINISH NO.1 PANEL 2. REMOVE CIRCUIT OPENING RELAY 3. INSPECT CIRCUIT OPENING RELAY CONTINUITY a. Using and ohmmeter, check that there is continuity between terminals STA and E1. If there is no continuity, replace the relay. b. Check that there is continuity between terminals +B and FC. If there is no continuity, replace the relay. c. Check that there is no continuity between terminals +B and FP. If there is continuity, replace the relay. 4. INSPECT CIRCUIT OPENING RELAY OPERATION Page 634 Camshaft Position Sensor: Testing and Inspection INSPECTION CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. b. Using an ohmmeter, measure the camshaft position sensor resistance between terminals. Resistance: Cold: 835 - 1,400 Ohms Hot: 1,060 - 1,645 Ohms If the resistance is not as specified, replace the camshaft position sensor. c. Connect the camshaft position sensor connector. Page 467 Cruise Control Switch: Testing and Inspection Denso Made System CIRCUIT DESCRIPTION When the cruise control main switch is turned off, the cruise control does not operate. WIRING DIAGRAM Step 1 Page 2058 CHART 21 Page 3243 How To Read Ground Points Page 553 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 601 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 170 Page 1362 Refrigerant: Fluid Type Specifications Type R134a Page 781 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1125 Transmission Speed Sensor: Description and Operation The No.1 vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 404 Brake Switch (Cruise Control): Description and Operation Denso Made System CIRCUIT DESCRIPTION When the brake pedal is on depressed, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP- of the ECU, and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. If the harness connected to terminal STP- has an open circuit, terminal STP- will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch is cut mechanically by the stop light switch, turning the cruise control off. (See DTC-12, Magnetic clutch Circuit) Page 1173 Page 145 Locations Page 2495 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3037 Vehicle Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Diagrams Fuel Return Line: Diagrams COMPONENTS CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. Page 458 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2511 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1888 Locations Page 897 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Diagram Information and Instructions Clutch Switch: Diagram Information and Instructions Page 1309 Coolant: Service Precautions 1. Toyota Long Life Antifreeze Coolant is recommended by the manufacturer for maximum protection. 2. Mixing green and red colored coolants is not recommended. Page 289 How To Read Ground Points Page 2469 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Locations Page 3103 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 424 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3338 c. Using an ohmmeter, measure the resistance between each terminal. Page 3187 Fuel Pressure Regulator: Service and Repair COMPONENTS REMOVAL 1. DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR 2. DISCONNECT FUEL RETURN HOSE FROM FUEL PRESSURE REGULATOR HINT: Put a suitable container or shop towel under the pressure regulator. 3. REMOVE FUEL PRESSURE REGULATOR a. Remove the 2 bolts and fuel pressure regulator. Torque: 8.8 Nm (90 kg.cm, 78 in.lb) b. Remove the O-ring. HINT: At the time of installation, please refer to the following item. Use a new O-ring. INSTALLATION Installation is in the reverse order of removal. Page 381 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR a. Disconnect the engine wire protector from the 3 brackets. b. Disconnect the ECT sensor connector. c. Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Page 796 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 3072 Vapor Pressure Sensor: Description and Operation CIRCUIT DESCRIPTION The vapor pressure sensor and VSV for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The ECM decides whether there is an abnormality in the evaporative emission control system based on the vapor pressure sensor signal. DTC P0450 or P0451 is recorded by the ECM when the vapor pressure sensor malfunction. Page 554 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2846 Engine Bank Identification Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Testing and Inspection Refrigerant Pressure Sensor / Switch: Testing and Inspection 1. SET ON MANIFOLD GAUGE SET 2. REMOVE GLOVE COMPARTMENT DOOR 3. DISCONNECT CONNECTOR FROM COOLING UNIT 4. SET VEHICLE IN THESE CONDITIONS: a. Running engine at 2,000 rpm b. Blower speed control switch at HI c. Temperature control lever MAX. COOL d. A/C switch ON 5. INSPECT PRESSURE SWITCH OPERATION a. Connect the positive (+) lead from the ohmmeter to terminal 1 and negative (-) lead to terminal 4. b. Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. Page 2202 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2599 Page 942 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1756 Radiator: Service and Repair On-Vehicle Cleaning ON-VEHICLE CLEANING Using water or a steam cleaner, remove any mud or dirt from the radiator core NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Maintain a distance between the cleaner nozzle and radiator core) Page 2744 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 598 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Service and Repair Crankshaft Main Bearing Seal: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 1064 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2158 Vehicle Speed Sensor: Testing and Inspection INSPECT VEHICLE SPEED SENSOR OPERATION a. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 2. b. Connect the positive (+) lead from the tester to terminal 3 and the negative (-) lead to terminal 2. c. Rotate the shaft. d. Check that there is voltage change from approx. 0 V to 11 V or more between terminals 2 and 3. HINT: The voltage change should be performed 4 times for every revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. Page 3302 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1987 How To Read Ground Points Page 1209 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Locations Page 1392 Underdash Fuses And Relays Details Page 2055 CHART 18 CHART 19 Page 2433 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 946 Camshaft Position Sensor: Description and Operation The Camshaft position sensor (G signal) consists of a signal plate and pick up coil. The G signal plate has one tooth on its outer circumference and is mounted on the exhaust camshaft. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. Page 2195 How To Read Ground Points Page 173 Engine Control Module: Description and Operation DESCRIPTION The Engine Control Module (ECM) controls all phases of electrical engine operation. In order to accomplish this control, the ECM relies on the input from a variety of engine operation sensors. The ECM compares input signals with those stored in memory to determine what steps should be taken to achieve maximum performance, fuel economy, and meet emission standards. The ECM outputs the necessary signals to the fuel system, ignition system, emission control systems, etc.. Battery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is OFF for use by the DTC memory and air-fuel ratio adaptive control value memory, etc. Page 2919 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 716 Knock Sensor: Testing and Inspection 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR a. Disconnect the knock sensor connector. b. Using SST remove the knock sensor. SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR a. Using SST, install the knock sensor. SST 09816-30010 Torque: 44 Nm (450 kg.cm, 33 ft.lb) b. Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 Nm (200 kg.cm, 14 ft.lb) 7. REINSTALL STARTER Page 373 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2006 How To Read Ground Points Page 3300 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 3076 a. Check that air flows from ports E to P, and does not flow from ports E to F. b. Apply battery positive voltage across the terminals. c. Check that air flows from ports E to F, and does not flow from ports E to R If operation is not as specified, replace the VSV. 5. REINSTALL VSV Page 2528 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 21 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2380 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.1 Vehicle Speed Sensor NO.2 Page 701 How To Read Ground Points Page 2387 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2336 Spark Plug: Application and ID Recommended Spark Plugs ND K16R-U NGK BKR5EYA Page 2265 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 2042 Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Page 696 Intake Air Temperature Sensor: Description and Operation The intake air temperature sensor is built into the air cleaner cap and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature. Figure 1 The lower the intake air temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value. The intake air temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temp. sensor are connected in series. When the resistance value of the intake air temp. sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. Page 1651 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS a. Disconnect the high-tension cords from the spark plugs. b. Using a 16 mm plug wrench, remove the spark plug. c. Using a spark plug cleaner or wire brush, clean the spark plug. d. Check the spark plug for electrode wear, threads damage and insulator damage. If abnormal, replace the plugs. Recommended spark plugs: ND: K16R-U NGK: BKR5EYA e. Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 0.8 mm (0.031 in.) f. Using a 16 mm plug wrench, install the spark plug. Torque: 20 Nm (200 kg.cm, 14 ft.lb) g. Connect the high-tension cords to the spark plugs. Page 1750 RADIATOR AND RELATED COMPONENTS Page 1932 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 428 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Diagram Information and Instructions Mass Air Flow Meter: Diagram Information and Instructions Capacity Specifications Fluid - A/T: Capacity Specifications A/T Fluid A340F Dry capacity ......................................................................................................................................... ........................................................................ 8.0 Qt Drain and Refill ................................................ ................................................................................................................................................. 2.0L (2.1 Qt) Page 3307 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions On-Vehicle Inspection Throttle Body: Testing and Inspection On-Vehicle Inspection 1. INSPECT THROTTLE BODY a. Check that the throttle linkage moves smoothly. b. Check the vacuum at each port. - Start the engine. - Check the vacuum with your finger. 2. INSPECT THROTTLE POSITION SENSOR a. Disconnect the sensor connector. b. Apply vacuum to the throttle opener. c. Using an ohmmeter, measure the resistance between each terminal. d. Reconnect the sensor connector. Locations Four Wheel Drive Selector Relay: Locations Automatic Differential Disconnect (A.D.D.) Component Locations Page 275 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 992 Knock Sensor: Description and Operation The knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. Ford Made System Cruise Control Switch: Testing and Inspection Ford Made System CIRCUIT DESCRIPTION When the cruise control main switch is turned off, the cruise control does not operate. WIRING DIAGRAM Step 1 Page 2423 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 2546 Engine Control Module: Testing and Inspection Related Diagnostic Procedures CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the EFI main relay (Marking: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Step 1 Page 773 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2072 CHART 30 Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Page 17 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 3102 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3325 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2475 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2335 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 20 Nm Page 2347 - Remove the adjusting shim with a small screwdriver and magnetic finger. b. Determine the replacement adjusting shim size by these Formula or Charts: - Using a micrometer, measure the thickness of the removed shim. - Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T...Thickness of removed shim A...Measured valve clearance N...Thickness of new shim Intake: N = T + (A - 0.20 mm (0.008 inch)) Exhaust: N = T + (A - 0.30 mm (0.012 inch)) Page 559 Key Reminder Switch: Description and Operation Current always flows to TERMINAL 12 of the integration relay through the DOME fuse. 1. SEAT BELT WARNING SYSTEM When the Ignition SW is turned ON, current flows from the GAUGE fuse to TERMINAL 6 of the integration relay. At the same time, current flows to TERMINAL (A) 2 of the relay from the GAUGE fuse through the Seat Belt Warning Light. This current activates the integration relay and, for Approx. 4-8 Seconds, current flowing through the warning light flows from TERMINAL (A) 2 of relay to TERMINAL (A) 7 to GROUND, causing the warning Light to Light up. At the same time as the warning Light Lights up, a buckle SW ON signal is input to TERMINAL (A) 3 of the integration relay, the current flowing from TERMINAL 12 of the relay flows to TERMINAL (A) 7 to GROUND and the Seat Belt Warning Buzzer Sounds for Approx. 4-8 Seconds. However, if the Seat Belt is put ON (Buckle SW OFF) during this period (While The Buzzer is Sounding), signal input to TERMINAL (A) 3 of the integration relay Stops and the current flowing from TERMINAL 12 of the integration relay to TERMINAL (A) 7 to GROUND is cut, causing the buzzer to stop. 2. KEY REMINDER SYSTEM With the Ignition Key inserted in the key Cylinder (Unlock warning SW ON), the Ignition SW still OFF and front LH door open (Door Courtesy SW ON), when a signal is input to TERMINAL (A) 10 of the integration relay, the Integration Relay operates, current flows from TERMINAL 6 of the relay to TERMINAL (A) 7 to GROUND and the Key Reminder Buzzer sounds. Page 1660 a. Check only the valves indicated. - Using a thickness gauge, measure the clearance between the valve lifter and camshaft. - Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake: 0.15 - 0.25 mm (0.006 - 0.010 inch) Exhaust: 0.25 - 0.35 mm (0.010 - 0.014 inch) b. Turn the crankshaft pulley 1 revolution (360°) and align its groove with timing mark "O" of the timing chain cover. c. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 8. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. - Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. - Position the notch of the valve lifter toward the spark plug side. - Using Special Service Tool (SST) (A), press down the valve lifter and place (SST) (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) HINT: ^ Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration. Page 2173 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 3071 Page 455 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2835 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Locations EFI Main Relay: Locations Underhood Fuses And Relays Page 981 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 1970 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 712 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1939 Camshaft Position Sensor: Testing and Inspection INSPECTION CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. b. Using an ohmmeter, measure the camshaft position sensor resistance between terminals. Resistance: Cold: 835 - 1,400 Ohms Hot: 1,060 - 1,645 Ohms If the resistance is not as specified, replace the camshaft position sensor. c. Connect the camshaft position sensor connector. Standard Value of ECM Terminals Engine Control Module: Testing and Inspection Standard Value of ECM Terminals Part 1 Of 2 Page 2620 A/F and 02 Sensor Identification Page 703 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 2251 Camshaft Position Sensor: Description and Operation The Camshaft position sensor (G signal) consists of a signal plate and pick up coil. The G signal plate has one tooth on its outer circumference and is mounted on the exhaust camshaft. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals and the actual crankshaft angle and the engine speed by the NE signals. Page 3145 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 2117 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 213 Air Bag Control Module: Service and Repair Removal and Installation REMOVAL NOTE: Do not open the cover or the case of the ECU and various electrical devices unless absolutely necessary. If the IC terminals are touched, the IC may be destroyed by static electricity. 1. REMOVE FRONT CONSOLE BOX 2. REMOVE LOWER CENTER COVER Page 2151 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1996 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2293 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Front Wheel Fastener: Service and Repair Front HUB BOLT REPLACEMENT 1. Remove front wheel. 2. Remove brake caliper and disc. 3. Remove hub bolt. Using Special Service Tool (SST), remove the hub bolt. 4. Install hub bolt. Install a washer and nut to the hub bolt, as shown in the illustration, and install the hub bolt by tightening the nut. 5. Install brake disc and caliper. 6. Install front wheel. Torque: 110 Nm (83 ft. lbs.) Page 2826 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 3247 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 984 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1976 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1852 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 1618 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 1091 Step 1 Page 1049 Step 3 Page 2906 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2657 CHART 29 Page 3296 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 15 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 3304 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 2830 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2207 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 3052 Catalytic Converter: Service and Repair 1. REMOVE CONVERTER a. Jack up the vehicle. b. Check that the converter is cool. c. Remove the bolts and nuts at the front and rear of the converter. d. Remove the converter and gasket. 2. REINSTALL CONVERTER a. Place new gaskets on the converter front and rear pipes, and connect the converter the exhaust pipes. b. Torque the bolts and nuts. Torque: 48 Nm (490 kg.cm, 35 ft.lb) Page 2088 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 607 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection INSPECT LOW OIL PRESSURE WARNING LIGHT a. Disconnect the connector from the warning switch and ground terminal on the wire harness side connector. b. Turn the ignition switch ON and check that the warning light lights up. If the warning light does not light up, test the bulb. Page 1070 Throttle Position Sensor/Switch: Description and Operation CIRCUIT DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, R, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in D position. Page 3112 a. Check that air flows from ports E to P, and does not flow from ports E to F. b. Apply battery positive voltage across the terminals. c. Check that air flows from ports E to F, and does not flow from ports E to R If operation is not as specified, replace the VSV. 5. REINSTALL VSV Page 2455 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2648 Page 2391 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 760 Page 397 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 1249 If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. f. Connect the high-tension cords to the ignition coils. 1. Assemble the holder and grommet. 2. Align the spline of the ignition coil with the spline of the holder, and push in the cord. NOTE: Check that the holder is correctly installed to the grommet and ignition coil as shown in the illustration. 3. Check that the lock claw of the holder is engaged by lightly pulling the holder. g. Connect the high-tension cords to the spark plugs. Secure the high-tension cords with the clamps as shown in the illustration. h. Install the intake air connector. i. Install the air cleaner cap and MAF meter assembly. Locations Page 282 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2237 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 1319 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Page 2400 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 613 INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP a. Place a new gasket on the air cleaner cap. b. Install the MAF meter with the 4 nuts. Torque: 8.5 Nm (85 kg.cm, 74 in.lb) 2. INSTALL MAF METER WITH AIR CLEANER CAP Testing and Inspection Wiper Switch: Testing and Inspection INSPECT FRONT WIPER AND WASHER SWITCH CONTINUITY w/ MIST: w/ INTERMITTENT: If continuity is not as specified, replace the switch. INSPECT INTERMITTENT OPERATION a. Turn the wiper switch to INT position. b. Turn the intermittent time control switch to FAST position. c. Connect the positive (+) lead from the battery to terminal 16 and the negative (-) lead to terminal 2. Page 479 Vehicle Speed Sensor/Transducer - Cruise Control: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2621 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction This Service Bulletin contains Oxygen Sensor (O2S) Monitor threshold values for all models from 1996 to 2003 and some 2004 models. Starting in 2004, the O2S Monitor threshold values can be found in the repair manual. These values are used when analyzing the O2S test results to determine the O2S condition. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description Checking O2S Test Results To view O2S test results, the O2S Monitor must be completed and the test results must be checked within the same key cycle. If the ignition key is cycled OFF, the O2S test results will be set to the minimum or maximum limits, and all test results will be erased. The O2S test results are stored in the ECU (SAE term: Powertrain Control Module/PCM) when the monitor is completed. The test results are static and will not change once the monitor is complete. The process for checking 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required SSTs NOTE: Additional Diagnostic Tester Kits, Program Cards or other SSTs may be ordered by calling SPX-OTC at 1-800-933-8335. Warranty Information Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 351 Wheel Speed Sensor: Description and Operation CIRCUIT DESCRIPTION The speed sensor detects wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system. The front and rear rotors each have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. Page 629 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 2519 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Refill With Filter ................................................................................................................................... ....................................................................... 5.8 Qt Without Filter ....................................................................................................................................... ........................................................................ 5.0 Qt NOTE: Listed capacities are approximate. Check fluid level after filling. Page 1161 Locations Fuse: Locations Underhood Fuses And Relays Page 2968 Vehicle Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 281 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1883 a. Apply battery positive voltage across terminals STA and E1. b. Using an ohmmeter, check that there is continuity between terminals +B and FP. c. Apply battery positive voltage across terminals +B and FC. d. Check that there is continuity between terminals +B and FP. If operation is not as specified, replace the relay. 5. REINSTALL CIRCUIT OPENING RELAY 6. REINSTALL LOWER FINISH NO.1 PANEL Page 2447 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2238 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 676 Crankshaft Position Sensor: Testing and Inspection NOTE: "Cold" and "Hot" in these sentences express the temperature of the sensors themselves. "Cold" is from -10 ° C (14 ° F) to 50 °C (122 °F) and "Hot" is from 50 °C (122°F) to 100 °C (212 °F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (NE(+) and NE(-)): Cold: 1,630 - 2,740 Ohms Hot: 2,065 - 3,225 Ohms If the resistance is not as specified, replace the crankshaft position sensor. Page 2649 CHART 24 Component Inspection Evaporator Temperature Sensor / Switch: Testing and Inspection Component Inspection INSPECT THERMISTOR RESISTANCE a. Place the thermistor in cold water, and while changing the temperature of the water, measure resistance at the connector and at the same time, measure temperature of the water with a thermometer. b. Compare the 2 readings on the chart. If resistance value is not as specified, replace the thermistor. Page 35 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 961 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3211 5. If you have no TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the fuel pump connector. 6. Pinch the fuel return hose. The pressure in high pressure line will rise to approx. 400 kPa (4 kg/sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTE: Always pinch the hose. Avoid bending as it may cause to hose to crack. 7. Turn the ignition switch to LOCK. 8. Disconnect the TOYOTA hand-held tester from the DLC3. Page 1710 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 3356 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Vapor Pressure Sensor Vapor Pressure Sensor: Testing and Inspection Vapor Pressure Sensor 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR a. Disconnect the vapor pressure sensor connector. b. Turn the ignition switch ON. c. Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5 V d. Turn the ignition switch to LOCK. e. Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR a. Turn the ignition switch ON. b. Disconnect the vacuum hose from the vapor pressure sensor. c. Connect a voltmeter to terminals PTNK and E2 of the ECM, and measure the output voltage under the following conditions: 1. Apply vacuum (2.0 kPa, 15 mmHg, 0.59 in.Hg) to the vapor pressure sensor. Voltage: 1.3 - 2.1 V 2. Release the vacuum from the vapor pressure sensor. Voltage: 3.0 - 3.6 V 3. Apply pressure (1.5 kPa, 15 gf/sq.cm, 0.22 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8V d. Reconnect the vacuum hose to the vapor pressure sensor. Page 2814 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Locations EFI Main Relay: Locations Underhood Fuses And Relays Page 2070 CHART 28 Page 1923 How To Read Ground Points Page 2494 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1662 Testing and Inspection Positive Crankcase Ventilation: Testing and Inspection 1. REMOVE PCV VALVE 2. INSTALL CLEAN HOSE TO PCV VALVE 3. INSPECT PCV VALVE OPERATION a. Blow air into the cylinder head cover side, and check the air passes through easily. CAUTION: Do not suck air through the valve. Petroleum substances inside the valve are harmful. b. Blow air into the air intake chamber side, and check that air passes through with difficulty. If operation is not as specified, replace the PCV valve. 4. REMOVE CLEAN HOSE FROM PCV VALVE 5. REINSTALL PCV VALVE 6. VISUALLY INSPECT HOSES AND CONNECTIONS Check for cracks, leaks or damage. Page 3329 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 1908 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1339 Fluid - Transfer Case: Service Precautions DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur. Page 941 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3251 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 3127 Idle Speed: Testing and Inspection INSPECTION 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected HINT: All vacuum hoses for EGR system, etc. should be properly connected. f. SFI system wiring connectors fully plugged g. Ignition timing check correctly h. Transmission in neutral position 2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL 3. INSPECT IDLE SPEED a. Race the engine speed at 2,500 rpm for approx. 90 seconds. b. Check the idle speed. Idle speed: 650 - 750 rpm If the idle speed is not as specified, check the IAC valve, intake air leakage and SFI system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL Page 2880 Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Locations Fuse Block: Locations Underhood Fuses And Relays Page 596 How To Read Ground Points Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Page 1810 INSPECTION 1. INSPECT WATER PUMP a. Visually check the air hole and drain hole for coolant leakage. If leakage is found, replace the water pump. b. Turn the pulley, and check that the water pump bearing moves smoothly and quietly. If necessary, replace the water pump. 2. INSPECT FLUID COUPLING a. Remove the 4 nuts and fan from the fluid coupling. b. Check the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling. c. Install the fan and fluid coupling with the 4 nuts. Torque: 5.5 Nm (55 kgf.cm, 49 inch lbs.) INSTALLATION Installation is in the reverse order of removal. Page 1189 INSPECT ONE TOUCH POWER WINDOW SYSTEM a. Disconnect the connector of the master switch. b. Connect the positive (+) lead from the ammeter to terminal 4 on the wire harness side connector and the negative (-) lead to negative terminal of the battery. c. Connect the positive (+) lead from the battery to terminal 9 on the wire harness side connector. d. As the window goes down, check that the current increases to approximately 7.0 A. e. Check that the current increases to approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens for some 4 - 40 seconds after the window stops going down, so that the check must be done before the circuit breaker operates. If the operation is as specified, replace the master switch. Using an ammeter with a current-measuring probe: INSPECT ONE TOUCH POWER WINDOW SYSTEM a. Remove the master switch with the connector connected. b. Attach a current-measuring probe to terminal 3 of the wire harness. c. Turn the ignition switch ON and set the power window switch in the down position. d. As the window goes down, check that the current increases to approximately 7.0 A. e. Check that the current increases to approximately 14.5 A or more when the window stops going down. Page 2089 Page 1997 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Testing and Inspection Power Door Lock Switch: Testing and Inspection INSPECT DRIVER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT PASSENGER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Locations Headlamp Relay: Locations Underhood Fuses And Relays Page 1935 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Service and Repair Air Bag(s) Arming and Disarming: Service and Repair CAUTION: * Work must be started 90 seconds after the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable of the battery, the SRS may be deployed.) * When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and audio system will be canceled. So before starting work, make a record of the contents memorized in the audio memory system. When work is finished, reset the audio systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup power supply from outside the vehicle. * Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during repairs. * Do not expose the steering wheel pad, front passenger airbag assembly, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Diagnosis and Testing. Page 3254 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 1338 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid Grade ................................................................................................................................................... .................................................... API GL-4 or GL-5 Viscosity .............................................................................................................................................. .............................................................. SAE 75W-90 Page 609 Page 117 INSPECT DAYTIME RUNNING LIGHT No. 4 RELAY CONTINUITY If continuity is not as specified, replace the relay. Front Wheel Speed Sensor: Service and Repair Front HINT: Pre runner is the described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB REMOVAL 1. REMOVE SPEED SENSOR a. Disconnect the speed sensor connector. b. Remove the 2 (4WD, pre runner) or 4 (2WD) clamp bolts holding the sensor harness from the steering knuckle, upper arm and side rail. Torque: Upper arm: 8.0 Nm (82 kgf-cm, 71 lbs.) Side rail: 13 Nm (130 kgf-cm, 9 ft. lbs.) c. Remove the speed sensor installation bolt from the steering knuckle. Torque: 8.0 Nm (82 kgf-cm, 71 lbs.) NOTICE: At the time of installation, please refer to the following items. There are no foreign objects on the sensor or the part of the knuckle to which the sensor is to be installed. - The sensor is installed flat against the knuckle when you tighten the bolt. - When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. NOTICE: After installation, check the speed sensor signal. Page 2595 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. Page 485 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 875 Secondary Locking Device (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. Connect connector Continuity and Resistance Check Continuity And Resistance Check (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the two leads of an ohmmeter to each of the check points. Continuity And Resistance Check If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. Continuity And Resistance Check (c) Use a volt/ohmmeter with high impedance (10 K Ohms/V minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 310 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: 1 Indicates Relay Block No. 1. Connectors not indicated are milky white in color. C : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. D : Indicates related system. Page 2252 Camshaft Position Sensor: Testing and Inspection INSPECTION CAMSHAFT POSITION SENSOR a. Disconnect the camshaft position sensor connector. b. Using an ohmmeter, measure the camshaft position sensor resistance between terminals. Resistance: Cold: 835 - 1,400 Ohms Hot: 1,060 - 1,645 Ohms If the resistance is not as specified, replace the camshaft position sensor. c. Connect the camshaft position sensor connector. Page 25 Finding A Short Circuit (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: A - Ignition SW ON B - Ignition SW and SW 1 ON C - Ignition SW, SW 1 and Relay ON (Connect the Relay) and SW 2 OFF (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION: a. Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. When replacing the internal mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). Voltage Check Page 844 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2120 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 308 The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points (EA, IB and IC shown) can also be checked this way. How to Read Power Source Page 75 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 920 B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "Case 1" Type where terminal retainer is pulled up to the temporary lock position (Pull Type) Insert the special tool into the terminal retainer access hole (Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector's shape (Number of terminals etc.), so check the position before inserting it. Water-Proof Type Connector "Case 2" Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. Page 1431 NOTE: After "Dinghy" Towing, or at the recommended distance limits, let the Engine idle for more than 3 minutes before operating the vehicle or resuming towing. NOTE: Vehicles that are Dinghy towable will not sustain internal damage to the transmission or transfer components, as long as speed/distance limits are observed. The transmission must be placed in the "neutral" position when Dinghy towing. Dinghy towing these vehicles does not eliminate the possibility of damage to other vehicle systems (Body, Chassis, Electrical Systems, etc.). Page 2685 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 602 Mass Air Flow Meter: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 1058 The "Current Flow Chart" images, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. Key to Diagrams Page 1959 Coolant Temperature Sensor/Switch (For Computer): Description and Operation A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at terminal THA also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the DTC P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). Page 295 Braking Sensor/Switch: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2908 Oxygen Sensor: Description and Operation DESCRIPTION To obtain a high purification rate for the CO, HC and NOx components of the exhaust gas, a three-way catalytic converter is used, but for the most efficient use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that it is always close to the stoichiometric air-fuel ratio. The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air-fuel ratio. This is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air-fuel ratio. When the air-fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN condition (small electromotive force: <0.45 V). When the air-fuel ratio is RICHER than the stoichiometric air-fuel ratio the oxygen concentration in the exhaust gas in reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive force: > 0.45 V). The ECM judges by the electromotive force from the oxygen sensor whether the air-fuel ratio is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to perform accurate air-fuel ratio control. The oxygen sensors include a heater which heats the zirconia element. The heater is controlled by the ECM. When the intake air volume is low (the temp. of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Page 2636 CHART 11 Page 2735 Mass Air Flow Meter: Service and Repair COMPONENTS REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER a. Disconnect the MAF meter connector and wire clamp. b. Loosen the air cleaner hose clamp. c. Disconnect the air hose from air cleaner cap. d. Loosen the 4 clips, and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. Page 2637 CHART 12 CHART 13 Page 668 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 1543 Oil Filter: Tools and Equipment Toyota Oil Filter Wrench Set AST tool# TOY 300 This set includes our tool numbers TOY640, TOY730, and M0219. With the TOY300 you have every gas engine Toyota/Lexus model covered between 1980 and 2009. - Covers all Toyota and Lexus vehicles 1980-2009, based on factory filters. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Kit Contains the Following Tools: TOY 640 - Toyota Oil Filter Wrench Specifications Firing Order: Specifications Firing order: 1-3-4-2 Page 3288 EFI Main Relay: Testing and Inspection 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY a. Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. b. Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION a. Apply battery positive voltage across terminals 86 and 85. b. Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Page 2850 System Diagnosis Air/Fuel Mixture: Testing and Inspection INSPECTION HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INITIAL CONDITIONS a. Engine at normal operating temperature b. Air cleaner installed c. All pipes and hoses of air induction system connected d. All accessories switched OFF e. All vacuum lines properly connected HINT: All vacuum hoses for EGR systems, etc. should be properly connected. f. SFI system wiring connectors fully plugged. g. Ignition timing check correctly h. Transmission in neutral position i. Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft.) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When doing the 2 mode (idle and 2,500 rpm) test, these measurement order prescribed by the applicable local regulations. 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot according to the table. Page 1169 Page 342 The Location of Splice Point I 5 is indicated by the shaded section. Shielded Cable K : Indicates a shielded cable. Pin Number Of The Connector L : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left from upper right to lower right lower left M : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component's location, e.g, "E" for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and B" for the Body and Surrounding area. N : Page No. Page 2558 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 2566 Voltage Check (a) Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1 ON C- Ignition SW, SW 1 and Relay on (SW 2 OFF) (b) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a Voltmeter. Page 2080 Wiring Harness Connector E : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component location, e.g, "E" for the engine component, "I" for the instrument panel surrounding area, and "B" for the body and surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g, IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. F : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block G : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts. H : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. I : Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red P = Pink G = Green W = White V = Violet 0 = Orange Y = Yellow BR = Brown SB =Sky Blue LG = Light Green GR = Gray The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point J : Indicates a wiring Splice Point (Codes are "E" for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). Page 533 Part 4 Of 4 Page 3100 Vapor Pressure Sensor: Diagnostic Aids Disconnection of Male and Female Connectors Disconnection Of Male And Female Connectors To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown in the image. 2. Disconnect Connector 3. Disengage The Secondary Locking Device Or Terminal Retainer. (a) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Page 2290 (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - For Non-Waterproof Type Connector HINT: The needle insertion position varies according to the connector's shape (number of terminals etc.), so check the position before inserting it. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device Page 3067 Terminal Retainer Push the terminal retainer down to the temporary lock position. Locking Lug (c) Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 4. Install terminal to connector (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position.