> TOYOTA n= ee MANUAL =MAINTENANCE = PREPARATION = SPECIFICATIONS =DIAGNOSTICS eee Vo) 60)" =a]FOREWORD This manual (Volume 1} contains maintenance, preparation, specifications and diagnostics procedures for ‘the 2000 CELICA. Applicable models: | ZZT230, 231 series For repair provedures for the engine, chassis and body, and electrical service procedures, refer to VOLUME 2 (Pub. No, RM744U2). ‘The manual is divided into 6 sections with a thumb index for each section at the edge of the pages. Please note that the publications below have also been preparad as relevant service manuals for the compo- nefts and systems in this vehicles. Manaal Nar Pi No, ‘UR4OE Automatic Transanie Repal Manual (Aug. 7989) ‘RRA 'URMOE, UBs1E Automate Transm Ropar Manoal (Aug, 7999) TBO ' 2000 GELIOA Electcal Wing Diagram WOT "2000 CELIGA New Gar Features THEFTS Allinformation in this manual is based on the fatest product information at the time of publication. However, ‘specifications and procedures are subject to change without notice. TOYOTA MOTOR CORPORATION ©1999 TOYOTA MOTOR CORPORATION Allrights reserved. This book may not be repro- duced oF copied, in whole or in part, without the \writion permission of Toyota Motor Corporation. First Printing: Jul. 14, 1989 01-290714--00,CAUTION This manual does notinclude all the necessary items about repair and service. This manualis made for the purpose of the use for the persons who have spacial techniques and certifications. in the cases that non-specialized or uncertified technicians perform repair or service only using this manu- ator without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer's vehicie. In order to prevent dangerous operation and damages to your customer's vehicle, be sure to follow the instruction shown betow. Must read this manual thoroughly. Itis especially important to have good understanding all the contents written in the PRECAUTION of “IN” section. ‘The service method written in this manual is very affective to perform repair and service. When Performing the operations following the procedures using this manual, be sure to use tools spe- ified and recommended. If using non-specified or recommended tools and service method, be sure to confirm safety of the technicians and any possibility of causing personal injury or damage to the customer's vehicle before starting the operation. Mfpart replacementis necessary, must replace the part with the same part number or equivalent part, Do not replace it with inferior quality. itis important to note that this manual contains various “Cautions” and "Notices" that must be ‘carefully observed in order to reduce the risk of personal injury duting service or repair, or the possiblity that improper service or repair may damage the vehicle or render it unsafe. Itis also important to understand that these "Cautlons” and "Notices” are not exhaustive, because it is important to warn of all the possibie hazardous consequences that might result from failure to follow these instructions.NOTE: The screon toned sections below are in VOLUME 2 (Pub. No. RM744U2). INTRODUCTION [Ita MAINTENANCE [ZW PREPARATION [Gail SERVICE SPECIFICATIONS DIAGNOSTICS (EIN Ay Ceypeey ALPHABETICAL INDEX < omINTRODUCTION HOW TO USE THIS MANUAL . ‘GENERAL INFORMATION . IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER REPAIR INSTRUCTIONS ....... GENERAL INFORMATION... VEHICLE LIFT AND SUPPORT LOCATIONS, FOR ALL OF VEHICLES PRECAUTION ..... HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS .......... (GENERAL INFORMATION HOW TO PROGEED WITH TROUBLESHOOTING «........... HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE TERMS . ‘ABBREVIATIONS USED IN THIS MANUAL... GLOSSARY OF SAE AND TOYOTA TERMS .. Ingo IN-95 N35 40INTRODUCTION ~_ HOW TO USE THIS MANUAL, HOW TO USE THIS MANUAL GENERAL INFORMATION 1. INDEX ‘An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you intnging you way trough he manual, he ection filand maior heading are von altho lop of every page. TN 2. PRECAUTION ‘At tho boginning of each section, a PRECAUTION is given that pertains to all repair operations contained in that section. Read thea precautions before starting any repair task. 3. TROUBLESHOOTING ‘TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the ‘cause. The fundamentals of how to proceed with troubleshooting are described on page IN-20. Be sure to read this before performing troubleshooting. 4. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spa- clal Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. 5. _ REPAIR PROCEDURES ‘Most repair operations begin with an overview illustration. It identifies the components and shows how the parts ft together. Example: QS Filer Cap <> Fiat Clovis Pin Gasket Clip Reservoir Tank Boot . Grommet Slotted! =a Pin ag levis ae Ring Washer Lock Nut Push Rod Cylinder Tem (rgfem, fbi) |: Specified torque ‘#Non-reusable part oeIN-2 JeTRODYENON —_HOWTOUSETHS MANUAL The procedures are presented in a step-by-step format: + The illustration shows what to do and where to do it. + The task heading tells what to do. +The detailed text tells how to perform the task and gives other information such as specifications and warnings. This format provices the experianced technician with e FAST TRACK tothe infomation needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed informa- tion. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to, 7. SPECIFICATIONS ‘Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They aré also found in Service Specitications section for quick ref- erence. 8. CAUTIONS, NOTICES, HINTS: + CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. + NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired. + HINTS are separated from the text but do not appear in bold. They provide additional information to help you perform the repair efficiently 9. SIUNIT The UNITS given in this manual are primarily expressed according to the Si UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N-m (310 kgt-cm, 22 ftibf)INTRODUCTION —_ IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION AND = ENGINE SERIAL NUMBER 1. VEHICLE IDENTIFICATION NUMBER ‘The vehicle identification number is stamped on the vehicle identification number plate and the certification label, as shown in the illustration. A: Vehicle Identification Number Plate B: Certification L abet 2 ENGINE SERIAL NUMBER ‘The engine serial number is stamped on the engine block, as ‘shown in the illustration.Seal Lock Adhesive INTRODUCTION. - REPAIR INSTAUCTIONS REPAIR INSTRUCTIONS GENERAL INFORMATION BASIC REPAIR HINT 2s (a) (b) () @ fe) Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Installation and removal of battery terminal: (1) Before performing electrical work, disconnect the negative {-) terminal cable from the battory. (2) Mit is necessary to disconnect the battery for in- spection or repair, first disconnect the negative (-} terminal cable. (3) When disconnecting the terminal cable, to prevent damage to battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it. (4) Clean the battery terminals and cable ends with a clean shop rag. Donot scrape them with a file or oth- er abrasive objects. (8) _ install the cable ends to the battery terminals after loosening the nut, and tighten the nut after instatla- tion. Do not use @ hammer to tap the cable ends onto the terminals. (6) Be sure the cover for the positive (+) terminal is property in place. Check hose and wiring connectors to make sure that they are connected securely and correctly. Non-reusable parts (1) Always replace cotter pins, gaskets, O-rings, oil seals, etc. with new ones. (2) Non-reusable parts are indicated in the component illustrations by the *#" symbol, Precoated parts Precoated parts are bolts, nuts, etc. that are coated with a seal fock adhesive at the factory. (1) If a precoated part is retightened, loosened or ‘caused to move in any way, it must be reccated with. the specitiod adhesive. (2) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads.INS INTRODUCTION —_AEPAIR INSTRUCTIONS (3) Precoated parts are indicated in the component il- lustrations by the "" symbol. (9) When necessary, use a sealer on gaskets to prevent leaks. (h) Carefully observe all specifications for bolt tightening torques. Always use a torque wrench, (| Use of special service toois (SST) and special service ma- terials (SSM) may be required, depending on the nature ‘of the repair. Be sure to use SST and SSM where speci- fled and fotlow the proper work procedure. A list of SST and SSM can be found in Preparation section In this manual. iN Medium CureniFuseandHighCuronifuce] () When replacing fuses, be sure the new fuse has the cor- Equal Amperage Rating rect amperage rating. DO NOT exceed the rating or use ‘one with a lower rating, ‘Symbot Part Name ‘Abbreviation — FUSE FUSE Pe MEDIUMCURRENTFUSE | M-FUSE —~e— | dich cunnentruse HAUSE Po FUSIBLE LINK FL an ese pee} | cncurereacer ce——_———___________inooerion__-_sparninsTaycriong {k) Care must be taken when jacking up and supporting the vehicle. Be sure to li and support the vehicle at the prop- er locations (See page IN-8). + Cancel the parking brake on the level place and shift the transmission in Neutral (or N position). + When jacking up the front wheels of the vehicle at first place stoppers behing the rear wheels. + When jacking up the rear wheels of the vehicle at first placa stoppers before the front wheels. + When either the front or rear wheels only should be jacked up, set rigid racks and place stoppers in front and behind the other wheels on the ground. + After the vehicle is jacked up, be sure to support it on rigid racks . It is extremely dangerous to do any ‘work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. () Observe the fallowing precautions to avoid damage to the following parts: (1) Do not open the cover or case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electric- ity) (2) To disconnect vacuum hoses, pull off the end, not WRONG CORRECT the middle of the hose, (3) To pull apart electrical connectors, pull on the con- nector itself, not the wires. (4) Be careful not to drop electrical components, such as sensors of ralays. if they are dropped on a hard floor, they should be replaced and not roused. (5) When steam cleaning an engine, protect the elec: i tronic components, al fiter and emission-related components from water. (6) Never use an impact wrench to remove or install WRONG CORRECT ‘temperature switches or temperature sensors. (7) When checking continuity at the wire connector, in- sert the tester probe carefully to prevent terminals from bending. (8) Whenusing a vacuum gauge, never force the hose ‘onto a connector that is too large. Use a step-down adapter for adjustment. Once the hose has been ozs stretched, it may leak aiINTRODUCTION — REPAIRWSTRUCTIONS (m) Installation and removat of vacuum hose: (1) When disconnecting vacuum hoses, use tags to identity how they should be reconnacted to. (2) After completing a job, double check that the vacu- um hoses are properly connected. A label under the hood shows the proper iayout. {n) Unless otherwise stated, all resistance is measured at an ll ambient temperature of 20°C (68°F). Because the resis- ea tance may be outside specilications if measured at high temperatures immediately after the vehicle has been run- hing, measurement should be made when the engine has cooled dawn. nyIN-8 INTRODUCTION REPAIR INSTRUCTIONS. VEHICLE LIFT AND SUPPORT LOCATIONS Front crossmember Rear axis beam : When jacking-up the rear and front, make ure the car is not carrying any extra weight. PANTOGRAPH JACK POSITION ‘SUPPORT POSITION Safety stand and swing arm type litINTRODUCTION ._ REPAIR INSTRUCTIONS IN-o HINT: Left and right set position Front and rear set position Atlachment dimensions 100 mm (8.94 in.) Plaoe the vehicle over the center of tha lit. + Align the cushion gum ends of the plate with the attachment lower ends (A, C) + Align the attachment upper end (B) with the front jack supporting point (t). 85 mm (3.35 in) 200 mm (7.87 in) imim I-10 INTRODUCTION =_FOR ALL OF VEHICLES FOR ALL OF VEHICLES PRECAUTION Negative Cable fa) (b) FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER ‘The CELICA is equipped with an SRS (Supplemental Re- straint System), such as the driver airbag, front passen- gor airbag assembly, side airbag assembly and seat bell pretensioner. Failure to carry out service operations in the correct se- uence could cause the supplemental restraint system to unexpectedly deploy during servicing, possibly leading to a sorious accident. Further, if mistake is made in servicing the supplemental restraint system, itis possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the cor- rect procedure described in this manual. GENERAL NOTICE (1) Malfunction symptoms of the supplemental re- straint system are difficult to confirm, so the diag- nostic trouble codes become the most important ‘source of Information when troubleshooting. When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before disconnecting the battery (See page Di-326). (2) Work must be started after 90 seconds from the time the ignition switch is turned to the "LOCK" post tion and the negative (-) terminal cable ts discon- nected from the battery. (The supplemental restraint system is equipped with a back-up power source so that it work is started within 90 seconds of disconnecting the neg- ative (-) terminal cable trom the battery, the SRS. may deploy.) When the negative (-) terminal cable is discon- nected {rom the battery, memory of the clock and audio systems will be cancelied. So befora starting work, make a record of the contents memorized by the each memory system. Then when work is fin- ished, reset the clock and audio systems as before. To avold erasing the memory of each memory sys- ‘tem, never use a back-up power supply from anoth- ‘er battery.nat INTRODUCTION ~_ FOR ALLOF VEHICLES (3) Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front pas- senger airbag assembly, side alrbag assembly and seat belt pretensioner should be inspected (See page AS~14, AS-28, and BO-111), (4) Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. (8) Before repairs, remove the airbag sensor It shocks are likely to be applied to the sensor during repairs, (©) _Neverdisassemble and repair he aitbag sensor as- sembly, stearing wheel pad, front passenger airbag assembly, side airbag assembly or seat belt preten- sioner. (7) Ifthe airbag sensor assembly, steering whee! pad, front passenger airbag assembly, side airbag as- ‘sembly or seat belt pretensioner has been dropped, or if there are cracks, dents or other defects in the case, brackel or connector, replace them with new ones. (8) Do not directly expose the airbag sensor assembly, steering wheel pad, front passenger airbag assem- bly, side airbag assembly or seat belt pretensioner to hot air or flames. (8) Use a volt/ohmmeter with high impedance (10kaV minimum) for troubleshooting of the electrical cl cuit (10) Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. (11) iter work on the supplemental restraint system is completed, check the SRS warming light (See page D326). SPIRAL CABLE (in Combination Switch) The steering wheel must be fitted correctly to the steering ‘column with the spiral cable at the neutral position, other- wise cable disconnection and other troubles may result. Refer to SR-19 of this manual conceming correct steer- ing whee! installation.eta INTRODUCTION. — FORALL OF VEHICLES. ‘STEERING WHEEL PAD (with Airbag) d) (ay @ @ @ 6) 6) When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. Storing the pad with its metallic surtace facing up- ward may leadto a serious accident f the airbag de- ploys for some reason. In addition do not store a steering wheel pad on top of another one. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous. Grease should not be applied to the steering whee! pad and the pad should not be cleaned with deter- gents of any kind, Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise, When using electric welding, first disconnect the air- bag connector (yellow color and 2 pins) under the steering columa near the combination switch con- nector before starting work. When disposing of a vehicle or the steering wheel pad alone, the airbag should be deployed using an SST bofore disposal (See page RS-16). Carry out the operation in a safe place away from electrical noise. Example:N13 INTRODUCTION FORALL OF VEHICLES (e) FRONT PASSENGER AIRBAG ASSEMBLY (1) Always store a removed or new front passenger air- bag assembly with the airbag deployment direction facing up. ‘Storing the airbag assembly with the airbag deploy- ‘ment direction facing down could cause a serious accident if the airbag inflates. (2) Never measure the resistance of the alrbag squib. (This may cause the airbag to deploy, which is very dangerous.) (3) Grease should not be applied to the front passen- ger airbag assembly and the airbag door should nat bbe cleaned with detergents of any king. (4) Store the airbag assembly where the ambient tern- erature remains below 93°C (200°F}, without high ‘humidity and away from electrical noise. (5) When using eleciric welding, first disconnect the air- bag connector (yellow color and 2 pins) installed on the assembly before starting work. {6) When disposing of a vehicle or the airbag assembly alone, the airbag should be deptoyed using an SST before disposal (See page RS-30). Perform the operation in a safe place away from electrical noise.(f) SIDE AIRBAG ASSEMBLY 0] @ @) 4) 8) © Always store a removed or new side airbag assem- bly with the airbag deployment direction facing up. Storing the airbag assembly with the airbag deploy- ‘ment direction facing down could cause a serious accident if the airbag deploys. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) Grease should not be applied to the side airbag as- sembly and the surface should not be cleaned with detergents of any kind. Store the airbag assembly where the ambient tem- perature remains below 83°C (200°F), without high humidity and away from electrical noise. ‘When using electric welding, first disconnect the air bag connector (yellow color and 2 pins) under the seat before starting work. ‘When disposing of a vehicle or the side airbag as- ‘sembly alone, the airbag should be deployed using an SST before disposal (See page RS~43). Perform the operation in a safe place away from electrical noise.INAS INTRODUCTION ~ _FORALLOF VEHICLES (g) SEAT BELT PRETENSIONER, a @) 8) @ 6) 6) @ Never measure the resistance of the seat belt pro- tensioner. (This may cause the seat belt pretension- 9 to activate, which is very dangerous.) Never disassemble tho seat belt pretensioner. Never install the saat belt pretensioner in another Vohiicie. Store the seat bell pretensioner where the ambient temperature remains below 80°C (176°F) and away from electrical noise without high humidity. When using electric welding, first disconnect the connector (yellow color and 2 pins) before starting work. When disposing of a vehicle or the seat belt preten- ioner alone, the seat belt pretensioner should be The seat belt pretensioner is hot after activation, so let it cool down sufficiently before the disposal. However never apply water to the seat belt preten- sioner.inte INTRODUCTION = FORALLOF VEHICLES (hb) AIRBAG SENSOR ASSEMBLY w (1) Never reuse the airbag sensor assembly involved in a collision when the SRS has deployed. (2) The connectors to the airbag sensor assembly should be connected or disconnected with the sen- sor mounted on the floor. If the connectors are con- ected or disconnected while the airbag sensor as- sembly is not mounted to the floor, it could cause undesired ignition of the supplemental restraint sys- tom. (8) Work must be started affer 90 seconds from the time the ignition switch is turned to the "LOCK" pos- tion and the negative (—) terminal cable is discon- nected from the battery, even if only loosing the set bolts of the airbag sensor assembly. WIRE HARNESS AND CONNECTOR: ‘The SRS wire harness is integrated with the instrument panel wire hamess assembly. All the connectors in the system are a standard yellow color. If the SRS wire har- ness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it as shown on page RS-~72.INA7 VEHICLES, FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: I large amount of unburned gasoline tlows into the converter, it may overheat and create a fire haz ard. To prevent this, observe the following precautions and explain them to your customer, @ ) «) @ fe) 0 @ a Use only unleaded gasoline, ‘Avoid prolonged idling. ‘Avoid running the engine at idie speed tor more than 20 minutes. ‘Avoid spark jump test. 41) _ Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine, ‘Avold prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible. Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. Avoid coasting with ignition tumed off. Do not dispose of used catalyst along with parts contaminated with gasoline or oil. IF VEHICLE 1S EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as two-way radios ard cellular telephones, observe the following precautions. (1) instal! the antenna as far as possible away from the ECU and sensors of the vehicle's electronic system. (2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve- bicle’s electronic systems. For details about ECU and sensors locations, refer to the section on the applicable component. (8) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid ‘tuning the antenna feeder parallel with other wire hamesses. (4) Check that the antenna and feeder are corractly adjusted, (5) Do not install powerful mobile communications system.Ina8. 4a INTRODUCTION — FORALL OF VEHICLES FOR USING OBD II SCAN TOOL OR TOYOTA HAND-HELD TESTER CAUTION: Observe the following items for safety reasons: Before using the OBD II scan tool or TOYOTA hand-held tester, the OBD Il scan tool's instruc- tion book or TOYOTA hand-held tester’s operator manual should be read thoroughly. Be sure to route all cables securely when driving with the OBD Il scan tool or TOYOTA hand— held tester connected to the vehicle. (1.6. Keep cables away from feot, padals, steering wheel and shift lever.) ‘Two persons are required when test driving with the OBD II scan tool or TOYOTA hand-held tester, one person to drive the vehicle and the other person to operate the OBD Ii scan toot or TOYOTA hand-held tester.INTRODUCTION ~ HOWTO TROUBLESHOOT ECU CONTROLLED IN-19 S¥ErEMS HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS GENERAL INFORMATION A large number of ECU controlied systems are used in the GELICA. In general, the ECU controlled system ts considered to be a very intricate system requiring a high ievel of technical knowledge and expert skill to troubleshoot. However, the fact is that If you procaed to inspect the circuils one by one, troubleshooting of these systems is not complex. if you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. This ‘manual is designed through emphasis of the above standpoint to help service technicians perform accurate and effective traubleshoating, and is compiled for the following major ECU controlled systems: ‘The troubleshooting procedure and how to make use of it are described on the following pages. Sym L_ Pao on bet 2 U2i0e Aonate Tamas sss [> owen ta oa [A Attack re Syn wi Ecru ata Fore Dion E60) one A Resta Sao ore 8. Cue Cone Stem oreo Body Control syeiam DES35. FOR USING OBD Il SCAN TOOL OR TOYOTA HAND-HELD TESTER + Before using the scan tool or tester, the scan tool's instruction book or tester’s operator manual should ‘be read thoroughly. + Ifthe scan tool or tester cannot communicate with ECU controlled systems when you have connected the cable of the scan tool or tester to DLC3, turned the ignition éwitch ON and operated the scan tool, there is a problem on the vehicle side or too! side. (1) If communication is normal when the too! is connected to another vehicle, inspect the diagnosis. data link fine (Bus@line) or ECU power circuit of the vehicle. (2) If communicat ‘Still not possible when the tool is connected to another vehicle, the problem {s probably in the tool itself, 0 perform the Sell Test procedures oulline in the Tester Operator's Manual.IN-20 INTRODUCTION ~ HOWTO TROVE! yT ECU CONTROLLED. ION — HOWTO TROUBLESHOOT EOI HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic pro- cedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each creult. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. icle Brought to Workshop) 1 Ask the customer about the conditions and the 1 istomer Problem oe environment when the problem occurred. Analysis = * feagerearas [A 5 sabagere te Code Chock ‘Symptom Simulation 23 Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes. {When the problem symptoms do not appear uring confirmation, use the symptom simulation method described later on.) 4 / Diagnostic Trouble Code Chart 45,6 Check the results obtained in Step 2, then confirm the inspection procedure for the system or the part which should be checked using the diagnostic trouble cade chart or the problem symptoms table. has been eliminated. (i! the problem is not reproducad, perform the confirmation test under the same conditions and in the same environment as when it occurred for the first time.) 6 _/Circuit inspection or Parts Inspection g 7 7 Check and repair the affected system or part in accordance with the instructions in Step 6. 8 / Confirmation Test 8 ~ After completing repairs, confirm that the problem" ~ HOWTO TROUBLES! 3U CONTROL Wat INTRODUCTION ~ Ho HOOT EC 0 1, CUSTOMER PROBLEM ANALYSIS in troubleshooting, the problem symptoms must be confirmed acourately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what tho problern symptoms are, itis extremely important to ask the customer about the problem and the conditions at the time it occurred, Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be Unrelated and the repair history, etc. may also help in some cases, so as much information as possible should ‘be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in Diagnostics section for each system for your use. Important Points in the Customer Problem Analysis. ‘¢ What —— Vehicle model, system name '* Whon —— Date, time, occurrence frequency ‘© Where —— Road conditions '¢ Under what conditions? —— Running conditions, driving conditions, weather conditions. ¢ How did it happen? —— Problem sympioms. (Sample) Engine contrat system check sheet, CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Check Sheet| —_[sepeotor's Qustomere Name ose [= [em ‘Odometer Feeding Ses CINo intial combustion, Go complete combustion Dincorrect frat ite Cling rpm i abnormal Nigh { tm) lowe Rough ding Corner Cieststion — Desextive ‘Cl Muttiorexpiosion (tter-re) Disurging ‘Aner sccolerator podal depressed Gator accelerator pedal retonsed —— C1During A/C operationNe INTRODUCTION — HOW TO TROUBLESHOOT ECU CONTROLLED ——_svsiEis 2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK ‘The diagnostic system in the CELICA fulfils various functions. The first function is the Diagnostic Trouble ‘Code Check in which a malfunction in the signal ciroults to the ECU Is stored in code in the ECU memory at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input ‘Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the CELICA, Sion Diagnostic Trouble | inout Signal Check | Diagnostic Test Code Check | (SensorGheek) _| Made Active Tes) leage (© (with Chock ° ° ‘Made Automate Transace (U240€) (© (wih Chock ° Mode) | Ainomate Tareale (U341E) (© with Chock ° Meda} | Ar-Lock Brake Systom with Electronic Brake Force Disitution (EBD) ° ° ° Suppernertal Restraint Sytem ° Cree Contra System ° Conta: In diagnostic trouble code check, itis very important to determine whether the problem indicated by the diag nostic trouble code is still oocurring or occurred in the past but returned to normal at present. in addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic ‘trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and atter the symptom confirmation to determine the current conditions, as shown in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in corract order and perform the diagnostic trouble code check, DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE [Diagnostic Trouble Code Check (Make a Confirmation | Diagnostic Trouble| Probie ot: cl robiam Condition [Diagnostic Trouble Problem symptoms} Same diagnostic | Problems still occurring in the diagnostic! [Code Display trouble code 16 /cheut Normalccdels | The problems slil occurring in a place a displayed other than in the diagnostic circuit [(The diagnostic trouble code displayed! first is either tor a past problom or itis al secondary problem} jo probiem "The problem occurred In the diagnostic symptoms exist circult in the past Normal code is | The problems stl occurring in a place displayed other than in the diagnostic circuit Normal code fs problem occurred Ina place other displayed than in the diagnostic circuit in the past- u lTRODUCTON — HOW To TROUELESHOOTECU CONTROLLED 2a Taking into account the points on the previous page, a llow chart showing how fo proceed with troubleshoot. Ing using the diagnostic trouble code check is shown below. This low chart shows how to utlize the diagnos. {ic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table. [Diagnostic wouble code check] [Making note of and clearing of the diagnostic trouble codes displayed Problem sympiomg | No problem symptoms exist exist Simulation tt using the sympiom simulation methods Diagnostic trouble code check SSS ‘¢ Diagnostic trouble code displayed | [= Normal code dieplayed Normal code displayed ‘© Problem symptoms exist ¢ Problem symptoms exist ‘* No problem symptoms exist Troubleshooting ot problemindicaied] {~ Troubleshooting of each System Normal }—-—— by diagnostic trouble code problem symptom Ita diagnostic trouble code was Gisplayed in the initial diagnostic trouble code check, it indicates thatthe trouble may have occurred in a wire hamess or connector in that circuit in the past. Therefore, ‘check the wire harness and con: nectors (See page IN-30).IN-24 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS, 3 SYMPTOM SIMULATION ‘The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, thorough customer problem analysis must bo carried out, then simulate the same or similar conditions and ‘environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong quess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the en- gine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc.. the prob- Jem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill, Since vibration, heat or water penetration (moisture) is likely cause for problem which Is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the ex- ternal causes are applied to the vehicle in a stopped condition. Important Points in the Symptom Simulation Test: in the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area ‘or parts must also be found out. To do this, narrow down the possible problem circults according to the symp- toms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is detective or normal and also confirming the problem symp- toms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. 1 | VIBRATION METHOD: When vibration seems to be the major cau: CONNECTORS Sightly shake the connector vertically and horizontally. WIRE HARNESS Slightly shake the wire hamess vertically and horizontally. The connector joint, fulerum of the vibration, and body ‘through portion are the major areas to be checked thorough- hy a ‘Swing Slightly PARTS AND SENSOR Vibrate Siightly Apply slight vibration with a finger to the part of the sensor considered to be the problom cause and check that the mat- function occurs. HINT: Applying strong vibration to relays may resultin open relays.DUCTION - HOWTO TROUBLESHOOT ECU CONTE WwTRODUCTION WTO TROUOLESHOOT ECU CONTROLLED 125 2 [near ‘METHOD: When the probiem seems to occur when the suspect area Is heated. [Heat the component that is the likely cause of the malfunction with a hair dryer or similar object. Check to seeif the malfunction loceurs. NOTICE: (8) Do not heat to more than 60 *C (140 *F). (Temperature Js limited not to damage the components) (2) Do not apply heat directly to parts in the ECU, high-humidity condition. ‘Sprinkle water onta the vahicle and check to see if the malfunc- tion occurs NOTICE: (1) Never sprinkle water directly into the engine compart- ‘mont, but indirectly change the temperature and hu: imidity by applying water spray onto the radiator front surface, 2) Never appty water directly onto the electronic compo- ents, HINT: lta vehicte is subject to water leakage, the leaked water may contaminate the ECU. When testing avehicle with a water leak- age problem, special caution must be taken, 3 | WATER SPRINKLING METHOD: When the malfunction seems to occur ona rainy day or ina 4 | OTHER: When a mattunction seems to occur when electrical load is excessive. ‘Turn on all electical toads including the heater blower, head Hghts, rear window defogger, etc. and check ta see if the mal- Hunction occurs.IN-26 INTRODUCTION — HOWTO TROUBLESHOOT ECU CONTROLLED _SYSTEMS 4 DIAGNOSTIC TROUBLE CODE CHART ‘The inspection procedure is shown in the table | below, This table permits efficient and accurate troubleshoot- ing using the diagnostic trouble codes displayed in the diagnastic trouble code check. Praceed with trouble- shooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes: ‘* DTC No. Indicates the diagnostic trouble code. ‘¢ Page or Instructions for checking and repairs. Indicates the page where the inspection procedure {fof each circuit is to be found, or gives instructions ‘© Trouble Area problem. * Detection item Indicates the system of the problem or contents of the problem. Indicates the suspect area of the played. The engine diagnostic trouble code chart is shown below as an example. DTC|CHART (SAE Controlled) HINT! Pararpeters listed in the chart may not be exactly the same as your reading dug to the type of instrument or ather factor Ifa malfunction cade is displayed during the DTC chack made, check the cirguil for that code listed in the table Car ar a agro nr ba eof er be repecon Te No” inthd DTC chart. Dido. _ 2. [| _ = Teaiehon wa [emer apace woke rot uctparcoms | ars o}o a Ta [haw dew Fes) Riseecreteaem | suarton o|o° Sagano rove | a arne cms Oo are, | irae serps ° i aaa Teena Spe ii nai ati wR ams | Ena Cott rr, Seppe eer o1o Pas | eam oon Tee “rorswaniian ce 3} Mais, | Be tenoven | Soaueenn ° - : * Opanr shorn tvehis pasion seneorciout 3 ue maton sats!INTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED SYSTEMS, 5, PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a "Normal" code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, considered that the prablem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. Circuit Inspection, Inspection Order Indicates the circuit which needs to be checked for each problem symptom. Check in the order indicated by the numbers, ¢ Page is located. Indicates the page where the flow chart for each circuit Circuit or Part Namo Indicates the circuit or part which needs to be checked, ‘¢ Problem Symptom PROBLEM SYMPTOMS TABLI Nsom Suspect Area ‘See page ‘Bre Engine doesnot crank (Doas no tat) . Statar and starter relay sraiz 1. EGM power source circuit, Dew? No ina combustion (Opes net sian) 2. Fuel pump coi! cul DetSt 8. Engine contol modute COM) a No complete combustion (Does not stan) 1. Fuel pump contr cout OFtst 1. States signal eu Dries Engine cranks nomial (Dict to star) 2. Fuel pump corel cveut 0b181 3. Compression eM engio 4. Stator signal cout Orta Cord engine (tcl stan) 2. Fuol pump contol creut on51 Het engine 1. Staner sonal ereuit Ontes 2. Fual purp cont! cxoat E51 7 1. WG signa crcl (Compwessor Grout [cee oor ina) 2 ECM pow source circuit 1G eigral cut (ro) 2. Fuel pump conieloreutN28 INTRODUCTION — HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 6 CIRCUIT INSPECTION How to read and use each page is shown below. ‘Diagnostic Trouble Code No. and Detection Item ‘© Circuit Description The major role and operation, etc, of the circult and its component parts are explained. DTC | Poa2s | Knack Sensor 1 Cirayj/Matfunction CIRCUIT DESCRIPTION o Scot teesoteothertekiéraematasng iver cruteapceten serach (Poca ernqanantbecoer coed wera asf Dor Ooo ae Sra grim engarencatnene ‘Brot eed ‘rapia ope waked conor am ‘Indicates the diagnostic trouble code, diagnostic trouble code set parameter and suspect area of the problem. WIRING DIAGRAM "© Wiring Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the ircuit Wire colors ara indicated by an alphabetical code. B « Black, L = Blue, R = Red, BR = Brown, LG « Light Green, V = Violet, G = Groen, O= Orange, W = White, GR = Gray, P = Pink, Y= Yoliow, SB = Sky Blue ‘The fist letter indicates the basic wire color and the second letter indicates the color of the stripe. pbaMTRODUCTION — HOW TO TROUBLESHOOT ECU CONTROLLED In-2o SYSTEMS. ‘ Indicates the postion of the ignition switch during the chack.| fe inspection Procedure 100% on Use the inspection procedure to determine i © anion Switch LOCK (OFF) ‘anion Switch ON the circuit is normal or abnormal, and, i it is ‘sta nee abnormal, use it to determine whether the Q tantionswteh st087 Q ‘orion Swien ace probiem is located in the sensors, actuators, aeVO_ ~ | } wire harness or ECU. Check comiouity between ternal KNK of ECM connoctor and body ground. PREPARATION: Romove i gave comparnant (Soe page SF). (©) Disconnect he E6 covmedtr ot ECM. ‘oHeck: Measure sekancobetwenn terminal KK of ECM connecter and dy ground. one «© Indicates the place to check the voltage ar resistance. ‘ Indicates the connector position to checked, from the front or back side. ‘Gheck from the connector back side. ‘Check from the connector front side. (without hamess) (with hamess) Inthis case, care must be taken not to bend the terminals. * Indicates the condition of the connector of ECU during the check. KNK KNK 6 Connector 6 Connector ‘Connector being chocked is connocted Connector being checked is disconnected.IN-30 INTRODUCTION ~ HOW.79 TROUBLESHOOT ECU CONTROLLED SYSTEMS HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1, CONNECTOR CONNECTION AND TERMINAL IN- ‘SPECTION + For troubleshooting, diagnostic trouble code charts or problem symplom table are provided for each circuit with detailed inspection procedures on the following pages. + When all the component parts, wire hamesses and con- nectors of each circult except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is per- formed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspec tion while using the symotom simulation method. + The instructions "Check wire harness and connector" and *Check and replace ECU” which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below ‘whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faully con- tact in the connector, and a connector terminal pulled out, etc. HINT: + Itis rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, care- {ully check the connectors of sensors and actualors + Faulty contact could be due to rusting of the connector terminals, o foreign materials entering terminals or a de- formation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the Condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no ab- normality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire hamess or con nectors. SHORT CIRCUIT: This could bo due to a contact between wire harness and the body ground or to a short circult occurred inside the switch, ete. HINT: ‘When there is a short cicuit between the wire harness and body ‘ground, check thoroughly whether the wire harness is caught in the body or is clamped properly.INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED IN-St SYSTEMS. * PullLightly Looseness of Crimping “25 2 GONNECTOR HANDLING When inserting tester probas into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good cara not to deform the connector terminals. 3. CONTINUITY CHECK (OPEN CIRCUIT CHECK) (@) Disconnact the connectors at both ECU and sensor sides. (b) Measure the resistance between the applicable terminals of the connectors. Resistance: 1 © or less HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally, 4. RESISTANCE CHECK (SHORT CIRCUIT CHECK) {a) Disconnect the connectors on both ends. (©) Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Resistance: 1 M@ or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. 5, VISUAL CHECK AND CONTACT PRESSURE CHECK (a) Disconnect the connectors at both ends. (&) Check for rust or foreign material, etc. in the terminals of the connectors. (6) Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly from the back.IN-32 INTRODUCTION ~ OW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS {d) Prepare atest male terminal and insert itn the female ter- minal, then pulll it out, NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. HINT: When the test terminal is pulled oul more easily than others, there may be poor contact in that section. 6, CHECK OPEN CIRCUIT For the open circult in the wire harness in Fig. 1, perform "{a) Continuity Check” or "(b} Voltage Check" to locate the section. {@) Check the continuity. (1) Disconnect connectors "A" and "C" and measure the resistance between them. In the case of Fig. 2, Between terminal 1 of connector “A” and terminal 1 of connector °C” -» No continuity (open) Botwoen terminal 2 of connector “A” and terminal 2 of connector °C" —» Continuity Therefore, itis found out that thera is an open circuit between terminal 1 of connector “A” and terminal 1 of connectar "C*. (2) Disconnect connector "B" and measure the resis- ‘tance between the connectors. Inthe case of Fig. 3, Between terminal 1 of connector "A” and terminal 1 ‘of connector "Bi" -» Continuity Between terminal 1 of connector "B2" and terminat { of connector °C” No continuity (open) ‘Therefore, It is found out that thera Is an open circult between terminal 1 of connector "B2" and terminal 1 of connector °C",INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED IN-33 SYSTEMS () Check the voltage. Ina circuit in which voltage is applied (to the ECU connec- {or terminal), an open circuit can be checked for by con- ducting a voltage chock. ‘As shown in Fig. 4, with each connector stil con- nected, measure the voltage between body ground and terminal 1 of connector "A" at the ECU 5V out- put terminal, terminal 1 of connector "B°, and termi- nal 1 of connector °C’, in that order. {the results are: 8V: Between Terminal 1 of connector “A” and Body Ground 5V: Between Terminal 1 of connector "B" and Body Ground 0V: Between Terminal 1 of connector "C* and Body Ground ‘Then itis found out that there is an open circuit in the wire har- hess between terminal 4 of “8° and terminal 1 of "C*. [Fos 7 7, CHECK SHORT CIRCUIT Ifthe wire harness is ground shorted as in Fig. 5, locate the sac- © (SHORT ®@ i tion by conducting a “continuity check with ground”. = 1 14 Fig. 6 Check the continuity with ground. (1) Disconnect connectors “A” and "C* and measure IO the resistance between terminal 1 and 2 of connec- ECU tor "A" and body ground. senor © © ® In the case of Fig. 6 ar 5 Between terminal 1 of connector "A" and body ground -» Continuity (short) Between terminal 2 of connector “A” and body one ground —» No continuity Therefore, itis found out that there is a short cirouit between terminal 1 of connector *A® and terminal 4 of connector "C*.IN-34 INTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED: SYSTEMS (2) Disconnect connector "B* and measure the resis- tance belween terminal 1 of connector "A" and body ‘ground, and terminal 1 of connector “B2* and body ground. Between terminal 1 of connector *A" and body ground ~» No continuity Between terminal 1 of connector "B2” and body ground + Continuity (short) ‘Therefore, it is found out that there is a short circult between terminal t of connector and terminal 1 of connector "C”. 8 CHECK AND REPLACE ECU First check the ECU ground circuit. fit is faulty, repair it. fit is normal, the ECU could be faulty, so replace the ECU with anor- ‘mal functioning one and check that the symptoms appear. (1) Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 @ or less (2) Disconnect the EGU connector, check the ground terminals on the ECU side and the wire hamess side for bend and check the contact pressure.___timmopuenion TEAMS TERMS ABBREVIATIONS USED IN THIS MANUAL = C xocam om ass renter Sa ne strain Get les con AG ecu Cota nan Sen ncs0 torte tS mcs ADD. oat Dsereco ORS ae ion at rm cvs High Coe Sprson rm donne eck eraser fat atonal J rv eer rm tows APO poss Mt AtonateTrainab random) Ae tons Wansin Fs ru ote rm pote rm anes Tavs cnive wrateupern en ioe Aa aac oot Anus Cpa 1 oar oar 00 tun Dead Goe an Bea as Bove Sioa oreo Top Den Coe eva iowa acum Sacra wae ca aware cs creation on cna Gowete Foran co con Owe ee —[eonetng eee co cat Of vy cn crt on ombtan ope coe ces Conte rane Sea peru Central Processing Unit ons chs Ratan yen ) ie — en chek be ov cea veDirect jection Distitwavies ignition [Double Over Head Gam [Dash Pot [Deed Sou ig Signal Processor Eteatroric Brae Fore Distribution Engine Corral And Measuromant Systam Electronic Contec Ores Edy Curent Oyramomater Electronic Contiol Unit teatro” Deposied Coating Eleatronie Driving Unt Electra Diesel ijecion Cont Electrons Fool nestion Engine Egr-vacuurn Modiletor Emergency Locking Reactor Engine Evectronic Spark Advance Elecironio trate Corto! System Bleavio Vaouun Regulating Vaio lenhaust Fuel economy Front-Engine Front-WhookDive Fuel Gage, Formed n Pace Gasket Fustble Line ust Parp Fuel Prossuce Up Fro Froni-Engine Rear Wheal-Ofive Fhyemeet Flywheel Dampor Front-Wheet-Drive, [aasoine [Ground EREEREE ET EST EPTFE ih Ati Conger faciaTERMS In-37 High Curren Fuse ig High Intensty Oschargo (Hoad Lamp) using Had To Heated Windahiald System ie Re Conve, TEPER HE Invegrated eit Ingest Diesel triecion a ee gation Imograted Ignition Assemoly inlako (Mariold, Va) Tntermitnt 513 ]2]5]5 Instrument Panel Independent Fear Suspension FPS s Junction Bioge sanction Connector Kick-Down, Local Area Network [untae Liquid Greta Disptay ght Emtng Diode Lat ot Hand Deve Length, Height With Lengrlife Coolant igotied Natural Gas. Low Liqutiog Peroloum Gas, imited Stn Ditferorta) Load Sensing Propoworing And Bypass Vao. Load Sensing Proporioning Valve Mam Miroptone Maiungion ineator Lar Micro Mutipupose utoiox Communication Sysern al Tranemission fw Mounting uwal Natural Aspiration umber SIN 2 Queuei WETRODUGTION TERMS, [oem (Grginal Equipment Manicuring fone Overhead Camshaft ory (Overhead Vatve ler (Option, los Qversize Pasy Proporioning And Bypass Vaio Pos Power Conuo} Systm Pov. ositve Granscaco Veniation ue Parking Broke Pes Progressive Power Steering PS [Power Steering PTO. Power Take-Off ReP. ack And Prion oo Relay Block oo esteuatng Gall Type Steering AF Relnforcoment aS Figid Front Suspension ARS. Rigid Reer Suspension RH. lght-Handt RHO. ght Hand Drive ALY Relay RON Read Only Noman Re Rear RA Rear_Engine Rear-Wngel Drive WD. Roar-wheol Ove [sore ‘Sean SEN ‘Sensor oo Staring injeton Control Syston 900 State O( Charge SOHC SPEC —{ SPI Supplemental Restraint Seton [ssa Specie Service Matos Trrte Body Elechonic Fuel injection Turbocharger FFOVOTA Computer—Controled System Ting Cots Valve Top Dead GarterRTODUCTION TERNS. Tew, Temperature TEMS "TOYOTA Elecronia Modulated Suspension rs Total Inoration Systm For Veneta Development Tranemission [TGYOTA Motor Carpoaton TOYOTA Motor Manufacturing Kentucky, In Taetion Cana Systm Tubocharge uncerarve juncersze Vacuum Corto! Valve Vani Vacuum Switching Valo Two Wheel Dive Vaca x2) [Fur whoo! Dive vance x)N40 WweRooUeTION TERMS. GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE~J1930 terms and abbreviations used in this manual in compliance with SAE rec- ‘ommendations, as well as their TOYOTA equivalents. ‘SAE TERMS TOYOTA TERMS (C-ABARE VATIONS [Ale Conctoner Air Cleanes, ACL Alc ection (at 7B, Batery Vatiage HAG, Imtarsooler carowotoe [Crank Angle [closes Leop [cam Angie ‘Ghtch Pedel Postion = (Goninuous Trap Oxiszer = ‘Glosea Tattle Poston LL ON, cle ON Direct Infection (0) Distributor Ignition ‘ala Link Convector 1 ‘ata Link Conractar 2 Data tink Connector 3 1: beck Connector 2: Teal Diggaoe's Comunicaion Lin (FDCL) 8,080 1 Diaanostio Connector Diagnoete Trouble Code Diagrostc Code. Diagnostic Test Mode ~ Engire Conval Lovet = Engine COU Clectonie Cond Ul) ‘Coolant Tomporature, Wator Temperature TH) ‘Boeticaily Erasable Programmable Read Only temory (EEPROM), Erasable Plagarnmable Read Only Memery (EPROM) (Gold Minture Heat (CMI), Heal Control Vabve (HOV) Exhaust Gas Rearevlaton (EGA) TOYOTA Distibuiorass ignition (TOW Eine Modication Erasable Programmable ised Only Memory Evaporative Emission Engina Maatcation (EM) Prograrnmetie Read Only Merry ROM) Evaporative Emission Cont! (EVAR) Fan Control Flash Electically Erasable Programmable aad Onty Memory Flash Erasable Programmable Read Only Memory Florio Fuel Fuel Pump FoolPunp, [Generator [Geouas [Ground (GND) ‘AtornatorIN weTeobueTION — TEAMS _ a angen oS — =, iat nk A Yoon Tint na oop eancoeaia = fe [usar eta Fee : se cre ne : is ieseaae aioe ne Jim pero se ais se Pere aris Pre Sr Soe a aA i Mare cne tis Com ne fast at te cw woe ions : ra Norra Semana aE i Tae Santas st ~~ Jurors : ie ae : wnat [er tts = ces [open Speen ooo Jase apa Tors ape non a 8 Sas Gaye anna Cnt cd cone cont oa ea an rss ron [rmoencoeinen - rae [reese : rnoi [Resa nS [= : sr fomrserrgres : PtOX Poviodic Trap Oxicizer eee Tene ta aren rey Tan ss ry fi or : foi enon en Pw Ee Speed Tesoro ss — Seen seas ey SFL | Sequential Muikiport Fuel Injection Elactronic Fual Injection (EF), Sequential Injection Sosa : See te : sen = SF | Scan Too! = ea Tea |e tan Sr ey ie aa ree LTCC Converter Clutch [Torque Converterrangmssion Control Module Ton Postion Transmission Range ‘Thora! Vacuum Valve ‘Trenemission EGU, EGT EU Troe Postion Bimetaile Vacuum Switching Valve (@VSV) Thermostatic Vacuum Switching Valve (TVS¥) Thwee-Wiay Catalytic (TWC) Voltage Regulator Vehicle Speed Senco: Fut TrotMAINTENANCE OUTSIDE VEHICLE INSIDE VEHICLE UNDER HOOD . ENGINE BRAKE ...... CHASSIS .MA-t MAINTENANCE — OUTSIDE VEHICLE, OUTSIDE VEHICLE GENERAL MAINTENANCE These are maintenance and inspection items which are considered to be the owner's responsibility. They can be done by the owner or they can have them done at a sarvice shop. ‘These items include those which should be chacked on a dally basis, those which, in most cases, do not require (special) tools and thase which are considered to be reasonable for the owner to do. Items and procedures for general maintenanca are as follows. f 1. GENERAL NOTES + Maintenance items may vary from country to country. Check the owner's manual supplement in which ‘the maintenance schedule is shown. + — Every service item in the periodic maintenance schedule must be performed. + Periodic maintenance service must be performed according to whichever interval in the periodic main- tenance schedule occurs first, the odometer reading (miles) or the time interval (months). + Maintenance service after the last period should be performed at the same interval as before unless otherwise noted. + Failure to do even one item an cause the engine to run poorly and increase exhaust emissions. 2. TIRES (a) Check the pressure with a gauge. If necessary, adjust. (b) Check for cuts, damage or excessive wear. 3. WHEEL NUTS ‘When checking the tires, check the nuts for looseness or for missing nuts. if necessary, tighten them. 4, TIRE ROTATION ‘Check the owner's manual supplement in which the maintenance schedule is shown. 5. WINDSHIELD WIPER BLADES ‘Check for wear or cracks whenever they do not wipe clean. If necessary, replace. 6 FLUIDLEAKS {a) Check undemeath for leaking fuel, oil, water or other fluid. (©) If you smell gasoline fumes or notice any leak, have the cause found and corrected. 7. DOORS AND ENGINE HOOD (a) Check that all doors and the tallgate operate smoothly, and that all latches lock securely. (b) Check that the engine hood secondary latch secures the hood from opening when the primary latch is released.NTE INSIDE VEHICLE GENERAL MAINTENANCE ‘These are maintenance and inspection items which ate considered to be the owner's responsibilty They can be done by the owner or they can have them done at a service shop. ‘These items include those which should be checked on a daily basis, those which, in most cases, do not require (special) tools and those which are considered to be reasonable for the owner to do. [EES toms and procedures for general maintenance are as folows. GENERAL NOTES + Maintenance items may vary trom country to country. Check the owner's manual supplement in which the maintenance schedule is shown. + Every service item in the periodle maintenance schedule must be performed. + Periodic maintenance service must be performed according to whichever interval inthe periodic main- tenance schedule occurs first, the odometer reading (miles) or the time interval (months). + Maintenance service after the last period should be performed at the same interval as before unless otherwise noted. + Failure to do even one item an cause the engine to run poorly and increase exhaust emissions. 2. LIGHTS (@) Chock that the headiights, stop lights, taillights, turn signal lights, and other lights are all working, (b) Check the headlight aim. 3. WARNING LIGHTS AND BUZZERS Check that all warning lights and buzzers function properly. 4. HORN Check that itis working. 5. WINDSHIELD GLASS ‘Check for scratches, pits or abrasions. 6. WINDSHIELD WIPER AND WASHER (a) Check operation of the wipers and washer. (b) Check that the wipers do not streak, 7. WINDSHIELD DEFROSTER Check that air comes out from the defroster outlet when operating the heater ar air conditioner. 8 REAR VIEW MIRROR Check that itis mounted securely. 9. SUN VISORS ‘Check that they move freely and are mounted securely. 10. STEERING WHEEL Check that it has the specitiod freeplay. Be alert for changes in steering condition, such as hard steering, excessive freeplay or strange noises. 1. SEATS (a) Check that the seat adjusters operate smoothly. (b) Chock that all latches tock securely in any position. (©) For fold-down seat backs, check that the latches lock securely, 12, SEAT BELTS (@) Check that the seat belt system such as the buckles, retractors and anchors operate properly and smoothly. (©) Check that the belt webbing is not cut, frayod, worn or damaged.13, MA-3 MAINTENANCE —_ INSIDE VEHICLE. ACCELERATOR PEDAL ‘Check the pedal for smooth operation and uneven pedal effort or catching, 14, @ ) 15. (@) (b) (© 16. CLUTCH PEDAL (See page CL-2) Check the pedal for smooth operation, ‘Check that the pedal has the proper freeplay. BRAKE PEDAL (See page BR-6) Check the pedal for smooth operation. ‘Check that the pedal has the proper reserve distance and reeplay, ‘Check the brake booster function. BRAKES Ata safe place, check that the brakes do not pull to one side whan applied. 7. fa) (b) 1B. fa) (b) PARKING BRAKE (See page BR-8) ‘Check that the lever has the proper travel ‘Ona safe incline, check that the vehicle is held securely with only the parking brake appliod. AUTOMATIC TRANSMISSION "PARK" MECHANISM ‘Check the lack release button of the selector lever for proper and smooth operation. (Ona safe incline, check that the vehicle is held securely with the selector lever in “P* position and all brakes released.MA UNDER HOOD GENERAL MAINTENANCE 1, GENERAL NOTES: + Maintenance items may vary from country to country. Check the owner's manual supplement in which the maintenance schedule is shown. + Every serice itom in the periodic maintenance schedule must be performed. FEES « _ ®erovic maintenance service must be performed according to whichever intarval inthe periodic main- tenance schedule occurs first, the odometer reading (miles) or the time interval (months). + Maintenance service after the last period should be performed at the same interval as before unless otherwise noted. + Failure to do even one item an cause the engine to run poorly and increase exhaust emissions. 2. WINDSHIELD WASHER FLUID ‘Check that there is sufficient fluid in the tank. 3. ENGINE COOLANT LEVEL ‘Check that the coolant level is between the "FULL" and "LOW" lines on the see-through reservoir. 4, RADIATOR AND HOSES {a) Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs. {b) Check the hoses for cracks, kinks, rot or loose connections. 5. BATTERY ELECTROLYTE LEVEL ‘Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case. 6. BRAKE AND CLUTCH FLUID LEVELS Check that the brake and clutch fluid levels are near the upper level line on the see-through reservoirs. 7. ENGINE DRIVE BELTS Check drive belt for fraying, cracks, wear or oiliness, 8. ENGINE OIL LEVEL Check the level on the dipstick with the engine turned off. 9. POWER STEERING FLUID LEVEL + Check the level. + The ievel should be in the "HOT" or “COLD” range depending on the fluid temperature. 10, AUTOMATIC TRANSMISSION FLUID LEVEL (a) Park the vehiele on a level surface. (bh) With the engine idling and the parking brake applied, shift the selector into all positions from "P” to "L", and then shift into "P" position. (c) Pull out the dipstick and wipe off the fluid with a clean rag. Re fluid tevel is in the HOT range. {d) Do this check with the fiuid at normal driving temperature (70 — 80°C, 158 ~ 176°F). HINT: Wait until the engine cools down (approx. 30 min.) before checking the fluid level after extended driving at high speeds, in hot weather, in heavy traffic or pulling a trailer. 11. EXHAUST SYSTEM {f any change in the sound of the exhaust or smelll of the exhaust fumes is noticed, have the cause located and corrected. MAINTENANCE = UNDER #000. ert the dipstick and check that theMA-S MAINTENANCE ENGINE ENGINE INSPECTION HINT: Inspect these items when the engine fs cold. 1, INSPECT DRIVE BELT (See page CH-2) 2. REPLACE SPARK PLUGS Zz (See page IG-1) 3. INSPECT AIR FILTER (a) _ Visually check that the air filter is not excessively dirty or oily, HINT: Oiliness may indicate a stuck PCV valve, NM necessary, replace the air cleaner element. (©) Clean the air filter with compressed air. First blow from the inside thoroughly, then blow off the outside of the element. 4. REPLACE AIR FILTER Replace the air fter with 2 new one. 5. REPLACE ENGINE OIL AND OIL FILTER (See page LU-3) 6. REPLACE ENGINE COOLANT (See page CO-2) 7, REPLACE GASKET IN FUEL TANK CAP (See page SF-28) 8. _ INSPECT FUEL LINES AND CONNECTIONS {See page SF-28) 9. INSPECT EXHAUST PIPES AND MOUNTINGS (See page EC-11) 10. ADJUST VALVE CLEARANCE (See page EMA)MAS MAINTENANCE -_ BRAKE BRAKE : INSPECTION 1. INSPECT BRAKE LINE PIPES AND HOSES HINT: Check in a well lighted area. Check the entire circumference and length of the brake hoses using a mirror as required. Turn the front wheels fully right or ieft before checking the front brake. (@)_ Check all brake lines and hoses for: + Damage Wear Deformation Gracks Corrosion Leaks Bends Twists (©) Check all clamps for tightness and connections for leak- age, (©) Check thal the hoses and lines are clear of sharp edges, moving parts and the exhaust system. (d) Check that the fines installed in grommets pass through the center of the grommets. 2, INSPECT FRONT BRAKE PADS AND DISCS (See page BR-18) 3. INSPECT REAR BRAKE PADS AND DISCS {See page BR-34) 4. INSPECT BRAKE LININGS AND DRUMS {See page BR-39)Maz MAINTENANCE — CHASS' CHASSIS INSPECTION = 1, INSPECT STEERING LINKAGE (a) Check the steering wheel freeplay (See page SR-8). (b) Check the steering linkage for looseness or damage. Check that: + Tie rod ends do not have excessive play. + Dust seals and boots are not damaged. + Boot clamps are not loose. 2. INSPECT STEERING GEAR HOUSING OIL heck the steering gear housing for oil leakage. 3. INSPECT DRIVE SHAFT BOOTS ‘Check the drive shaft boots for clamp looseness, leakage or damage. 4. INSPECT BALL JOINT AND DUST COVERS (a) Inspect the ball joints for excessive looseness. + Jack up the front of the vehicle and place wooden blocks with a height of 180 - 200 mm (7.09 - 7.87 in.) under the front ties. —<— + Lower the jack until there is about half a load on the front coll spring. Place stands under the vehicle for safely. seo + Check that the front wheels are pointing straight ahead, and block them with chocks. + Using a lever, pry up the end of the lower arm, and check the amount of play. Maximum ball jolnt vertical play: ‘Omm (0 in.) {i there is play, replace the ball joint. (©) Check the dust cover for damage.MAINTENANCE - CHASSIS 8. CHECK TRANSAXLE OIL (FLUID) Visually check the transaxle for oil (fluid) teakage. If leakage is found, check for the cause and repair. 6 REPLACE TRANSAXLE FLUID fa) Mit Replace transaxle oil (C56: See page MX-4) (C60: See page MX-4) tb) AT: Replace transaxle (transmission) ftuld. {U240E: See page DI-157) (U941E: Sea page DI-220) 7. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY It the vehicle is mainly operated under the rough, muddy road conditions, Tighten the seat mounting bolts and front and rear suspension member retaining bolts to specified torque. + Seat mounting bolts Torque: 37 Nem (375 kgf-cm, 27 ft-lb) Front suspension member ~ to body mounting bolts Torque: Bolt A113 N-m (1,162 kgt-cm, 83 ft-lbf) Bolt B 187 N.m (1,600 kaf-cm, 116 ft-lbf) Rear suspension member ~ to body mounting bolts Torque: Bolt A 80 N-m (816 kgf-.cm, 59 ft-lbf) Bolt B 130 N-m (1,326 kgf-cm, 96 ftibtPREPARATION MAINTENANCE ......... ENGINE MECHANICAL EMISSION CONTROL ..... SFI... fe COOLING ....., LUBRICATION .. IGNITION STARTING . CHARGING CLUTCH eee MANUAL TRANSAXLE (C56) . MANUAL TRANSAXLE (C69) . ‘AUTOMATIC TRANSAXLE (U240E) .. AUTOMATIC TRANSAXLE (U341E) ... ‘SUSPENSION AND AXLE BRAKE... STEERING 1.00.20... : ‘SUPPLEMENTAL RESTRAINT SYSTEM PP-74 BODY ELECTRICAL sees BODY «0... AIR CONDITIONING cesses: PROBS5 MAINTENANCE EQUIPMENT var Tongue wrench PREPARATION —_MAWTENANGE. PPPP-2 PREPARATION —_ ENGINE MECHANGAL ENGINE MECHANICAL SST (Special Service Tools) “Ge0s7 00100 01 Pon Seal Cater ‘WH2O1-010S5 valve Guise Bushing Remover & Re placer 35 ‘GH201-A10RD Valve Siem 03 Seal Replace: "DEN0D7O0RD Valve Siring Compressor (op2G2o0020) Atacwnent ‘WH215-70010 Grenkchat Paley Wong Too! (9322-30010 Confecting Rod Busting Rerrover 4 Replaces GRBAAS03) OF Sea) & Boating Ropiacer (WS 22010 _ Cranvahat Fant OVSead Peplacer (9309-37010 Wansssion Bearing Replaces {79330-00021 Gompanion Flange Hotding Toot Deis 30010 OW Prassure Swich SockotPREPARATION. —_ ENGINE MECHANICAL PP3 (09950-50012 PulerG Sat (09951-05010) Hanger 150 (09952-05010) ‘Sita Arm (05953-65020) ‘Canto Blt 150 (03954-05020) ‘law Nez (05850-70010 ands Sot (09951-07100) Hardie 100RECOMMENDED TOOLS ‘DHORO-OAIR) Engine Bog Bovis Foreuepeing engine A = B= ‘200-0810 Enane Aaa =a ee ae ose Php Sl. Pg fr vac Few, false ” LS __]EQUIPMENT [emer Cope gauge PREPARATION. — ENGINE MECHANICAL Ng Piston ring groove Paton pinhole of pistonPP SSM (Special Service Materials) (08826-00080 ‘Beal Pocking Back or oqulvalont (aP@ (08826-09100 Seal Packing 17826, ‘THREE OND 12828 cr muivalont (FPG) (08833-00070 Tanase 1324, ‘THREE BOND 124 or equivalentEMISSION CONTROL EQUIPMENT PREPARATION — EMISSION CONTROL —[— wren 190 = ease [rec Hove clipperPP PREPARATION SFI SFI SST (Special Service Tools) ve s ae SnD Poin Pale T ry GREAT wasn Wang To Sl +— apete? Gs336-00n Tom 7 —_ a (09268-41250) Teint COOLING SST (Special Service Tools) PREPARATION ~_ COOLING. P11 DO) WABO- 1010 Fair Saricn Tot bat eoo FOO ‘ma3I-1OIO Punch : "09960-10010 variable Prva Sa 5 (09963-00800) Fae (09963-01000) Pinto FAPPaz RECOMMENDED TOOLS ‘08082-00040 TOYOTA Elecicel Tester.ppg PREPARATION. COOUNG EQUIPMENT [ECT ewich, ThewrostatPpa COOLANT em Capacity ‘lassiicaton Entylone-gycol base Engine coolant 15.7 free (6.0 US ls, 5.0 imp. als) 5.6 Hers (5:9 US ls, 4.9 Imp. cis) re (6.2 US ls, 6.2 Imp. ls) 5.8 Bra 6.1 US ats, .4 imp als)5 PREPARATION — LUBRICATION. LUBRICATION SST (Special Service Tools) (09218-06501 ONFier Wrench Pps (9816-30010 OF Pressure Swish Soa! @)Pras EQUIPMENT [on prosaxe Torque wrench Feet gas onPREPARATION — LUBRICATION Pp-17 LUBRICANT om capaci Cessation Engine i APlgrade Si, Enorgy-Canserving or LSAC mu Brain and est rade engine ol. SAE SW-30 isthe best rok 3,7 ters (29US @s, 3.9 mp.qs) for your vehicle, or good fuel aconemy.and goed 85 lta (37 USA, 3:1 Imps) stating incold woator, 4Alirs (4.88 qs, 4.0 mp.ats) 42ers 46S fs, 58 imp.) nyt 4.1 ers 43S qs, 3.6 np.as) ABtiore 5.1 US qt, 42.mp.fs)PRAg PREPARATION — IGNITION ) IGNITION RECOMMENDED TOOLS : ‘H082-O0GI) TOYOTA loccal Toul: ===> 05200-00010 Ergo Agata. =e == WwP20 PREPARATION —_ IGNITION EQUIPMENT5 STARTING PREPARATION STARTING SST (Special Service Tools) PP-21 [ ‘08286 A601} tyecton Pu Spine Sheth Puiet & 6 ‘O5B10-38140 Starter Magnet Swich Nut Wronch “ (09820-00030 Aternsior Fos’ Boning RplacerPp.2e RECOMMENDED TOOLSPP-23 ) EQUIPMENT ~PP24 = SHAR CHARGING SST (Special Service Tools) TH28STOIOtopoten Pump Canchah Bong —— ‘Cone Replecer (9286-4GD11 Wjcton Purp Spine Sha F TaRa0 OOO Aton Rowe Bearing Palor "Aierata’ Rar Bearing Roplaoar (09820-63010 “AkarnatorPulay Set Wal Wiech Set = HO Es © {PPPST-06350)Pepner aS © (WHS a0556) Foxoooe ‘ppsorTe0I0 tarda Le Ye aT) Wand 109PP-25 PREPARATION — 5 RECOMMENDED TOOLS 7 "05082-00040 TOYOTA ElecicalTesior [L]PP-26 PREPARATION. GHAAGING EQUIPMENT tan spect ravtyonuge Caco newman aby [Bot teraton geune ren erave wrench ect tor (Sip eng). Buh) CLUTCH PREPARATION —_ cLUTCH SST (Special Service Tools) PP-27 eS ‘09023-00100 Union Nut Wrench Om ‘Gierine ae (9301-00210 Guich Gada Too! — es» "09333-00013 Gutch Diaphragm Sprig AigrarP28 PREPARATION = CLUTCH RECOMMENDED TOOLS (05031-00030 Pin Punch - "09905-00013 | Snap ing Pere———___________rmeraramon yon EQUIPMENT Vout Dit incest — =PP-30 LUBRICANT tem ‘Gapacty Clasatioaton ferake td = SAE J1703 oF FMVSS Na. 116 DOTSPREPARATION — MANUAL TRANSAXLE (C56) MANUAL TRANSAXLE (C56) ‘") gst (Special Service Tools) PP3t [ Gea S010 Cranahah ForeaTSea aa abate ))= apace R26 10010 Canlahah Fant Rew Boning aneieson case Stsoal ee) ~ 30H O0010 GF Sal Paar Sopa san bon bata 2 ‘i506 TaGDD eo Dive Gow Raga BIGOT Tanarialow a Vana Bening irae pert ar aing 22, Perce ee Teo oo (Qo 0001i) Posse Pe GRS0-Sno14 VOVOTAhcnaneTararanaoe Dir abode bara ee = (@ISi-B2ID0) Owdive Boag oper (@RSI-S2Ia) Oi Gas Raploee E) CHSGISDOTT OtorbalPrabed naar ‘3sbs-b00Ti bis Fa Fear Bale Cone Tapeh a dab ) Repiacer ‘Ousput shat soar racial Dall bearing GRaIa-RiOia Tota Worm Boreg Par Tp sata bateg Dierepda!apered roller baaing ule race(09628-62011 Ball Joint Puller ‘Bi diven gear "08636-20010 Upper Bal Joint Duet Cover No. hub aloo absorb placer ‘OF7KO-28001 Front Suspension Busting Too TWansaro case ol weal Sot S (05710-08081) ‘Bushing Replacar ‘Beanng Ramever SET Rate RASTER sac ae ia PIR ey ace eile Re aia rae mane Bs bee oo é ( ‘OBeenece. acai Waa saa acon ts Sina oad iis ray aa vane © Diterenti tapered roller Bearing © bia eas armaPREPARATION ~_MANUAL TRANSAXLE (056) PP-33 S C5STI0S)Rapacar Spas han beatng DOoq _ srcoiaH Fever srne 2200 20Gerr (09951-00680) Repacor iro pared rote bead cer race (Taneal caon sd) {G9951-00710) Resear Diora peed rote bearing oer race ranension cave ee) 2 "9950-7010 Rene or BL (9951-07150) Mana 10PP-34 PREPARATION — MANUAL TRANSAXLE (656, RECOMMENDED TOOLS = aT Torque Wench (S0KgRea) ‘itera proead (9031-00080 Pia Puneh sa ‘Soap Ring No.t ExpanderEQUIPMENT Dial inccator wih magnetic base [Fevteroue Mirorntor PREPARATION — MANUAL TRANSAXLE (956) ~— PP-35 Torque wrench Magnotie ager —t [Wogan book o inter abjectPP-26 LUBRICANT item PREPARATION — MANUAL TRANSAXLE (C56) _ cnval wensade ot iwi Otter oid Capacity 1.91ters 2.0 US qs, 1.7 inp. at Gasteaton API AL-4 or t-S ©) [sne7sw-20PP-37 PREPARATION — MANUAL TRANSAXLE (058) SSM (Special Service Materials) = ) aa eR, Tan THREE BOD 8 reat Tewmtsen cae Taseseeen (re) caso cover (08833-00080 Adhocte Tose “THREE BOND 1544 LOCTITE 242 or equvaantPP-38 PREPATATION — MANUAL TRANSAXLE (C60) MANUAL TRANSAXLE (C60) SST (Special Service Tools) ina S0G10 Grater Pawar Sal ))= fepacer “Qua aa ron bearing ner race ‘(8326-10010 Crankahak Foot & Rear Beasog “ianariesion cave ol eoul ‘Qupur anak Font beaing | Se = CeO ‘Dorel tapered roler bearing {08316-00011} Pepianer Pow TH52S2010 Tanemison OF Pig Tapul shales rei bal boning tn TSS S010 DRel Oive Poon Rear Fane ma SS ‘Bearing Repiacar ‘ ‘BSD OST Fear ie Bhat Polar ~ (09520-00040) Shocker Front axle a == = GION) Racine mies (09521-00020) Rod wih Grin Front axle a Rearexe TBI00-01010 Ore Shak Remover Atasmark Trg ah yor TESD0-24610 ania Bide Gow Sah Farid hah Pater oo (isiosa0AG) Shaster Ser T6ENDAOIO Ove Sra Boot Cap Too Frode ah oD TESTITO1T Baar Kia Shak Beatrg Fonover ForanP57 PREPARATION —__ SUSPENSION AND AXLE 585 35010 oar De Pen Fae CSSD Fh ars Rata Ta Fad at Ausd, ® (os0i tay aE wa ® wets ati) Pao to ote 5610 Woot own Ge Fone SS) ~ IOS Pian Par Fada Fort shat Pst suporeen RTT a ir Fone feta GEG taro Pa Fane a= — Toro saa Bape Bag ToS Feat one geshe r (ORO D31A Being Remar Base HT Cala Conroe Fai ope Ae& pow worn (09727-00010) Beh Set _ Ly writ Wasa(©9727-0031) Compressor — ‘aii Rabat Front Sg pe ar Favicon ‘isso bop Ore Sra es Fania so» Front ce shat HISE-O0010 aa aver Tanai at er rane = = Rapa Sa Lie © CRETE) oper Fem aie {GHBSIERISD) pcr File GiRSI- OO) opie Fit ie e) Fret ie shat =— T9980-600RO — Repca So Na? Fatale Se Oo Oa 2S@0r e) (GiRS1-OT3O) Pepe 72 B550-70010 Rando Sa Fei ae BYE Front dive shh 2 fo (00951-07150) Handle 1505 PREPARATION —_ SUSPENSION AND AXLE RECOMMENDED TOOLS PP-59 co (9025-00010 Torque Wrench (80 hom) 2 (05042-00010 Tan Soaket Tad A [5000-04020 Ere Sng Doce * ‘Seap Rig Nast Expander (05905-00013 Snap Fing PerPP-60 ramon gusresion one EQUIPMENT Das nat win gon ao a oe whPP-61 PREPARATION —SUSPENSIONAND AXLE LUBRICANT Dive sit tease Casacty ‘Aoplcton AZZ-FE (AT): Joubostisiie Color actor 10-1209 99-4202) Inboardskle Colon Yotow cone 120-190 9(63-67 02) E-FE (WT) and BEIGE: outboard ise Coior-ack 115 =1959 (41-4200) lnboard sido ColoreGray 100-1209 (95-4200)Pp62 BRAKE SST (Special Service Tools) PREPARATION BRAKE S HOB-AOTOD Union Na Wench TO a (92176011 Crarvanaht Puley Replacor 9520-00031 Rear Ante Shat Puler a ‘@9521-00020) Red wih Grip wai wa ‘07703-30010 Brake Shoe Retarn Song Too! (9709-29018 LSPV Gauge Set GHTIE-00010 Shoe Hold Down Spring Diver ‘9751-36011 Brako Une Union Nat 10x 12 mm Wena ‘09843-19040 Dlagnenle Check Wire No ‘08950-60150 ABS Actuator Checker andPAEPARATION — DrAKe ‘B3W0-O1I50 ABS Adio Oca Bhar ° PP-63 "09990-00300 ABS Actvator Ohecker Sub—harness ? a "07990-00360 _ ABS Actuator Chesker Sub-harmans ePP-64 RECOMMENDED TOOLS PREPARATION — BRAKE, ‘09082-00040 TOYOTA Elecifeal Tester ss = aa anor eyindorPP-65 PREPARATION — sRAKE EQUIPMENT era wrench Brake ee Diaingcator Sate ee Brake dso Brcko doym gauge |PP-66 PREPARATION = BRAKE. LUBRICANT we can Cone me : Tacs is SGOTSTEERING ) SST (Special Service Tools) PREPARATION —_ STCERING PP-67 ‘03608-04051 Fron Hub ater Bearing Cone = ‘Replacar (09612-00012 Rack & Pnion Soong Rack PS gear Housing Stand ‘G5612-20010 Power Storing OW Seal Pier PS gear (09612-22017 Va Handle Bearing Replace PS gear ‘08616-00010 Steering Worm Basfing Adusing PS gear Socket "09617-35020 Power Storing ing Na Wrench PS pear ‘ORGRI=1DO7I —_Stering Rack Of Seal Tet Tool PS gear ‘09631-20051 Steering Rack Cover "C= PS gear ‘05631-20081 Seal Ring Too! PS gear (9631-20020 Power Stewding Hose Nut PS vane pum 1417 mm Wrench Sat PS gear "93635-00020 Power Storing Hace Nut Wrengh PS gear ‘09640-10010 Power Seeing Preceure Gauge Powe’ sieang ts SetPREPARATION — STEERING. (eai-01010) Gauge Ay (09661-01030) ‘Atachrrent & (09641-01060) “aiachrent (09923-10010 ‘Viable Open Wrench PS oar (05950-50012 Poler Sat TTisteeng corn (05951-05010) Hanger 160 (05952-03010) (05953-05020) “Center Bak 160 ‘Giaw Woz (09950-60010 Peplacer Set (09951-00210) (05951-00240) PS year (5951-00280) Replacer 28 PS vane pump PS gearPREPARATION ~ STEERING PP-69 S Coos caaaS Fanaa Facer © (oRsi- 888) Pann as er a © wn aay Ra Fea ) PP-81 PREPARATION — BODY. RECOMMENDED TOOLS = g 50 010 Pr = Tesi-enaI moos (CHS0-050) Weve Pow oz GE ID Howl Car <_)-Pp-92 PREPARATION. 990) EQUIPMENT [cp remover Torque wrench oa ng pers To aveld surface damage Aces ape, To avoid surtace damage Dovtia— sox tape acesive Cleaner Regulator hance cite Mouliog Honcho Movida Piano wire Windstile sever on rush Puy spent wooden tock o sitar obec For tying bot piano wire end ase shew To avoid euraoe damage (09) it break Seat be prtonsioner spose! Tce Wa: 185 men (7 281m) neem: 360 0 (4.17 fn) ‘Seat bet pretensioner isposal Tice with ls wheat Wie: 185 mm (7.28 in) inner cam 380 mm (14.17 1) Seat bok pretnsionercisposat LMiny! bag [Sabet pretensionerdeposal5 LUBRICANT hen e.PR-84 PREPARATION — BODY SSM (Special Service Materials) ‘08833-00070 Atnesive 1324, ‘THREE BOND 1324 or equhaient 08853-00030 Three coment back or oquNalont ‘08850-00801 Winasiok Gnas Aahestvo Set orequvaient5 PREPARAT ICO! AIR CONDITIONING SST (Special Service Tools) PP-85 (7110-58060 ‘ir Gandiioner Sonica Tool Set (71778050) tigerant Charging Gauge (07117-88660) rgerant Charging Hoo (onii-#8070) Foligerant Charging Hose (07117-88080) Ferigerant Charging Hose ‘tity (Green) (OnLs7-58060) Ftigarant Brain Servico Vave (om1i7-se080) ‘Gui Disennnact Adaptor Discharge (iam. 16 mm) (717-8090) “ui Disconnect Adaptor “Suston (em. 1S eam) “(@nL17-58070) Taint 07116-33360 ‘Ges Loak Detector hasan (07112-76060 ‘Magneto Ckton Biopper \wde=%Q0osg ‘o7112- 66040 ‘agratis Guick RemoverPREPARATION — AR CONDITIONING. (07114-8402) Soap Ring Pls ‘7114-84010 Soap Ring Pies ‘970-0015 AC Gul soit Pubes Ro. ‘WPETO-ODIDS NE Quick sit Pater to Cis tbePP-87 LPAEPARATION — A CoNpmowNG y RECOMMENDED TOOLS ~~ "09082-00040 _ TOYOTA Bocca Tester & (9216-0002) Bat Tension Gage — ‘09216-60030 Beit Tension Gnuge Catiathermistor, ECT switch Magnetic ouch Megoatic ouchPP39 PREPARATION —_ AIF CONDITIONING LUBRICANT Capacity Classicavon = NO-OIl 8 or equivatont aocotane) 2002 (44 thee)—MEMO—SERVICE SPECIFICATIONS AUTOMATIC TRANSAXLE (U240E) .. AUTOMATIC TRANSAXLE (U341E) . SUSPENSION AND AXLE BRAKE . STEERING ‘SUPPLEMENTAL RESTRAINT SYSTEM BODY ELECTRICAL .) ss SERVICE SPECIFICATIONS _—_ STANDARD BOLT. STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH @) @ ® E ©)SPECIFIED TORQUE FOR STANDARD BOLTS TOR ey cis | arate [hen Tosa oaponge ba ete A 7 = 7 sa a anes 2 us | ws me wt ~{ ° e = mt =o 2 te oma a “ e a rs ar ts ie oa : ° 1 ces enw | en : ts | swe | se * is mlm | ee oT 12 18 39 600 43 88 870 48 ‘ s ee ‘s ue owe mw | “ * ¢ 7 @ eee | : us eee | ome ® tas So @ » | wm & oo 12 1.25 cy 730 53 80, 810 58 “ ‘s fou w]e tm “ “8 mee | : ° ¢ + as a 3 bs moe fmm ~| * ts a ° is Som | we mw “ ve we tot fee tame te is mm | — 3 is @ ee ea aw} te ie S068 | wm 2 a fo | eta * 1a nr a] f is re i oe rr ® us wie | ts ° as See w | we i som 2 | mm 2 Ye | le tm | testo Ts as ea a ml ve ow om | & wR 2 us tao ne | smeSTANDARD BOLT ) HOW TO DETERMINE NUT STRENGTH = ‘Nut Type (Old Standard Hexagon Nut Class ‘Cold Forging Nut Cutting Processed Nut aN a ven No Mar (w Washer No Mark 6N ©O/fA|~ 8N eo] § |-- nN 12N *:Nut with 1 or more marks on one side surface ofthe nut HINT: woes Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas- .)sifcation number when tightening parts with a bolt and nut, Example: Bolt = 4T Nut = 4N or moreSs-4 MAINTENANCE SERVICE DATA Front aie and suspension Balliointvarical pay. _SEAVICE SPECIFI mer Maximum |r (Qn)Maanres TORQUE SPECIFICATION Pact Bghtonod nm | __ Werem Ter Fee ants Sy 7 = te Free emperor xB) oma] 1s 82 (See page MA-7) Bolt 187, 1.600 416 ear usporson mens Body eal ao a6 2 (Seepoee WA2) sors) 120 128 &83-6 SERVICE SPECIFICATIONS —_ENGIYE MECHANICAL, ENGINE MECHANICAL SERVICE DATA Ta-FE ‘81250 pm STO | 1.500kPa (163 kolon?, 218 ps Minimum | 1,000 (102 haem. 145 ps Compression Diterence of rossure betwoon sach cyindar | 100 KPa (1.0 gem? 15 pal or less pressure mace: ‘81260 pm STO | 1400KPa(143 bien? 208 ps Minimum | 1,000 kPa (10.2 kor? 145 ps) Diterence of pressure betwwen each eyinder | 110 KPa (1 ken? 16 pl) Oss 172-FE: atid make f0.15—0.25 mm (0.006 -0.010 in} Exhaust | 0:25~0.38 mm (0010-0014) Vana clearance adjusting shin ‘80.08 | 5.960 mm (0.1992In) ‘80.08 | $.080 mm (0.2000 0.) ‘No, 10 | 5.100 mm (0.2008) Mo. 12 | 5.120mm 0.20160) ‘No. 14 | 5,140 am (.2024in,) ‘No. 16 | §.160 mm (0.2031 in) No. 18 | §.180 mm (0.2099 in) ‘80,20 | 5.200 an (0.2047 In) No, 22 | 5.220 0m (0.2085in) No. 24 | 6.240 mm (0.20630) ‘No.26 | 5.260 (0.2071 in) ‘80.28 | 6.280 om (0.2079 in) ‘No. 20 | 5.300 mm (0.2087 in) ‘No. 32 | §.320 mm (0.2094 in.) No. 24 | 5.240m(O2102i0 ) 10.36 | 5360 am 0.211010} ‘vewe clearance Ho. 38 | §:380 mn (0.2116 in) No. 40 | 5.600 mm (0.2126in) No. 42 | 5.4200m (0.2134in) io.44 | 5.440 mm (O2142in) fio. 46 | 5.4600mm (0.2180in) No. 48 | 5.480 a (02187 In) ‘No. $0 | §.500 mm (0.2165 in) Ho. $2 | 5.520 min (0.2179in) No. $4 | 5.540 mm (0.2181 in) No. 86 | 5.560 mm (0.2188 in) No. 58 | 6.580 mm (0.2197 in) No. 60 | 6.600: (0.2205 in} No. 62 | § 620mm (02213 in} No 64 | 640.mm (0.2220 in) No. 65 | 5.880.mm (0.2278 in) No. 68 | 5.680:mm (0.2238 in) No. 70 | 8 700 mm (0.2244 in) No. 72 | 8.720: (0.2252 in.) No. 74 [5.740.m (0.260 in)ss7 SERVICE SPECIFICATIONS —_ ENGINE MECHANICAL azz-Ge: ‘atcod Intake [0.15 -0.25 mm (0.008 -0.010m) Exhaust | 0.5~0.45 mm (00140018 In} Valve clearance adusting sim No, 00 | 2.000 mm (0.0787 in) ‘No, €2 | 2.020 mm (0.0798in No. 04 | 2.040 men (0.0806 in} No. 06 | 2.060 mm (0.0811 in) ‘No. 08 | 2.080 mm (0.0818 in) No, 10 }2:100.men (00827 in) No 12 |2.120:mm 0.0896 in} No. 14 |2.140:mm (0.0843 in) No. 18 {2.160:mm (008601) ‘No, 18 | 2.180 mm (0.0868) No, 20 | 2.200 mm (010866 ,) No. 22 | 2220 mm (0.08740 ) No, 24 | 2.240 mm (0.0882in) ‘No. 28 | 2-260 mm (0.08905) ‘No, 28 | 2.280 mm (0.0898) ‘uo. 30 | 2.300 (0.0906 in) No. 2 }2:320°mm (0.0913 n) Ho. 94 | 2:40 mm (0.0821 in) ‘0.96 | 2.380 mm (0.0928) Vane clearance "No, 38 | 2.880 mm (0.0937 in} No. 40 | 2.400 men (0.0948in) No. 42 | 2420 mm (0.0853in) No. 44 | 2.440 mm (0.0961 in) No. 46 | 2-460 mm (00960in) No, 48 | 2-480.mm 0.0076 in) ‘No, 50 | 2.500 mm (0.0984 i) io, $2 | 2520 mm (.0992n) No, 6 | 2540 mm (0.1000 in ) No. 86 | 2.860. (0.100810) ‘No. 88 | 2.580 mm (0.10160) ‘No, 60 | 2600 10m (0.102¢in) No. 62 | 2620.0 0.1031 in} No. 64 | 2640 me (0.1089in) Mo. 66 | 2660:ma (0.1047 in 3 No. 68 | 2680 mm 0.1058 in) No. 70 | 2.700 mm (0.1088 in) ‘No. 72 | 2.720 nm (0.1071 in) Ho, 74 | 2740 mm (0107810) No, 78 | 2.780 mm (0.1087 in) No. 78 | 2780 mm (0.t094in}) ‘No. 80 | 2800 mm (0.1102in) W2-FE 10-18" BIOC @ ia zz-08: 8-2" BTOC@ ae "700 «50 pen Chale tong at 16 aks 122.8 mm (4.827 0) [Camshaft Uming sprocket waar (wchain) Minimum | 97.3 mm (3.894) [Crankshat timing sprocket waar {wi chain) trim | 51.6 mm (2.034 in) Woor ‘Maximum | 1.0 mm (0088 in}SERVICE SPECIFICATIONS. — ENGINE MEGHANIGAL warpage ‘Masamm [0.05 mm (0.0020in) vate seat Refacing angle 90", 45", 75° Contacting angie 8 Contacting wid 1.01.4 mm (0.029 ~ 0.055 in} Resicvary width Minioum take | 3.3 mm (0.199 in) Exhaust | 3.2 mm (0.128 in) Vive gud busing bore diameter 122-8 Ovinder head STO | 10.286 — 10.206 mm (0:4049--0.4057 in) 015.005 | 10.355 ~ 10.358 mn (04068-04077 in) 222-Ge ‘970 | 10.488 10.508 mm (0.41201 -0.41962in) (015 005 | 10.686 10.856 mm (0.41488 ~00.41559in) yincer head bot ameter altension portion STD | 9.0 ~8.2 mim (0.954 ~0,962in.) Minimum | 2.0 mm (0354 in} 122-FE: Insita ameter 5.510 ~ 5.530 mm (02163-02177 In) avo gute bush | Protusion naight 87-81 mm (0.942—-0.958 in) ing 2IT-0E: Insite dametor 5.500~ 5.518 mm (0.2165 ~0.2172in) Pratusionneight 183 - 187 mm (0.602~ 0.6180) 12z-FE: Vale overaltongth 570 take | 68.85 men (2.4902 in Exhaust | 88.69 mm (3.4917 In) Maru itano | 88.98 mm (8.4789 in.) Exhaust | 28.38 mm (3.4788 in.) Valve tace angle 4s Stem diameter Intake | 5.470 ~ 5.485 ma (0.2154 ~ 0.2159in) Exhaust | 465 ~ 5 a80.mvn (0.2152 ~ 02157 in) Stem oll larance ‘810 taka | 0.025 ~ 0.060 mm (0.0010 ~0.0024 .) Exhaust | 0.030~ 0.065 mm (0.0012 ~ 0.0028 in) ‘Maximum intake | 0.08 mm (0.0031 i) Exhaust | 0.10 mm (0.0099 in) Margin thickness 10 | 10mm (00281n) vee iene | 0.7 (0.028 in.) 227-08 Valo ovealienath 810 tone | 131.2 (4.82) Exhaust | 111.7 mes (4.396 in) Mira itako | 10:9 mm (4.386 in.) Exhaust | 1113 mm (4.382 in) alo face angio 40s Sion diamater Intake | 5.460 ~ 5.475 mm (0.21496 ~ 0.21586 in) Exhaust | 6.445 ~ 6.470 mm (0.21697 ~ 021695 in) Siem oll dearance STD tnake | 0.025 ~ 0.058 mm (0.00008 ~ 0.00228 in) Exhaust | 0.030 ~ 0.068 mm (0.00118 ~ 0.00048 in) ‘axinam | 0.10 mm (0.0089 0.) Margin tikes 81D | 1.0 mm (0.039 in} Minimum | 07 ren (0.078 in)SERVICE SPECIFICATIONS —_ ENGINE MECHANICAL, Tear Devision Maaimun | 1.6 em (0.068 in Angle (Reterence) Maxam | 2° Free length 45.90 mm (1.807) Intale tonsion at 33.6 rom (1.828 (n.) Masimar wes tasion at 24.6 mm (0.969 in} 199.6 154.4 (14.2 -16.8 gl, 13-248 2449 -276.1N 255 ~28.1 gl, $5.2 ~61.9161) 272-GE: Deviation Maximum | 1.6 mm (0.063 9} Angie (Reterence) Maxie | 2° Fees ienght Intake | 45.4 mm (1.830 in) exhaust | 46.5:mm (1.831 In) tale tonalon at 8.5 mem (1516 in) Intake |220-2- 243.50 (225~24.7 ky, 49.6 ~55.5 1b) Eshaust | 208.2 ~ 205,81 (21.2-20.4 Kgl 47.6~ 52.6 01) Maximam working tension Inisko at 27.3 mm (1.075in} | 533 ~589 N (4.4 ~60.1 Ko, 119.9 ~ 192.5) Exhaust al 28.5 mer (1.122 a} | 495.5 ~ 548.5N GOS ~59 kof, 11. — 129.9) zr Liner diameter 90.906 -30.978 mm (12191-12195) Liter bore ameter 231,000 ~ 38.028 rum (1.2208 — 1.2215) Oi clearance TD | 0028-0058 mm (0,009 - 0.0023 n) Maximum | 0.073 man (0.0031 la) Tae: Torus clearance ‘S10 | 0.040 - 0.098 rm 0.0016 0.0087 in) Mari | 0.41 nm (0.0043 in) Journal ol clearance: STO | 0095 0.072 mm (0.0014 0.0028 in) Maximum | 0.10 mm (0.0038 in) Joumal ameter Not | 34.449 - 34.468 mm (1.9563 1.9509 in) ‘Others | 22.49 ~22 665 rem (0.8088 0,9041 in irce runout Maximum | 0.09 mm (0.0012in) [Cam be hei ‘STD Intake | 44.393 ~ 44.499 mem (1.7454 1.7480 in) Exhaust | 43.761 ~49,861 mm (1.7225 1.7268 in) ‘Minium inane | 44.18 un (1.7398) Ewnaust | 43.6 me (1.7169 in} 227-6: Thrust elearance 10 ]004~0.14 mm (0.0018 ~0.0058 in) Masienr | 0.18 min (0.0059 in) Journal of clearance ‘sTD No.1 | 0.035 0.078 mun (0.00138 -0.c0289 in) ‘ethers | 0.098 0.072 mn (0.00138 0.00289 in) Maximum | 0.4 mm (0.098 in.) Jounal ameter No.1 | 34-449 94.485 mm (1.85626 — 1.95869.) ‘Otners | 27.949 27,968 mn (1.10095-~ 1.10038 in) Chee rout Mexinum | 0.08 mm (0.0012in) Com lobe neigh ‘STD inate ‘No.1 ] 40.607 ~ 40.707 men {1.9586 ~ 1.59878 in) No.2 | 98,769 98.869 men (1.82352 1.82755 in) shaust ‘No.1 | 40.019 - 40.119 mm (1.57275 ~1-57888in.) [No.2 | 98:063 36.058 mm (1.52732 ~ 1.58125 in) Mima intake No.1 | 40-45 mm (1.8925 in.) ‘No 2 | 38:61 mi (1.820% in.) Exnaust ‘No.1 | 80.96-mm (1.8699 in) No.2 | 30.71 mm (1.8240%n.) Intake manta | warpage Maximum [0.10 (0.00893, Exhaost manta Maximum [ 070 man (0.0276 a,83-10 1Z-FE: ykindor noad surface warpage Moxienum Cylinder tore ameter sto Maximum 12 poitod hoa bearing cap sub-assembly bolt hamster at tension portion STO 0.05 mm (0.0020 in) 79,000 ~79.013 mm {8.1102~3.1107 In} 7.013 mm @.A107 ny 7.97.5 0mm (0.287 ~0.296in) ‘8812.0 mm (0,048 in| rom tha piston head Piston oP clearance sro Masimum Piston ring roove clearance Paton ring end gap STONo.1 No.2 i Maximum No.1 No.2 al Miimum | 7.3m (0.267 in) oyinder tock | a7 ee ‘Cytnder head surtace warpage Masitnum | 0.05 mm (0.00200) ‘Oyinder bore diameter STO | 82.000 ~82.013 am 3.2283 3.22891) Maximum | 82.019 mm (3.2289 19) ‘2pointed haad bearing cap sub-assembly bok ameter ‘attension pation STD | 73-75 em (0.287 -0.286in) Miieoum | 73 eum (0.287 in) 12Z-FE: Piston ameter ‘af 25.6 me (1.008:n} from the piston head | 78.925 ~ 78.995 mm (2.1073~ 3.1077 in.) Picton oi clearance STD | 0.065.~ 0.088 mn (0.0026 ~0,0095 in) Maxum | 0:10 mm (0.0039 in) Piston ag groove clearance 0.630 ~ 0.070 me (0.0012 - 0.0028 0.) Pisin ring ond 80 STO No. 1 |025~0:35 mm (0.0088 ~ 0.0138 in} No.2 | 0.28 ~ 0.50 mm (0.0128 0.0197:n) it 0.15 - 0.40 em (0.0088 - 0.0187 in} Maxi No.1 | 1.05 mom (0.0413 in) No.2 | 1.20 mm (0.0472 in} Plton an piston ‘01 | 1.05 mm (0.0818 in) 109 222-GE: Paton cfamator 81.975. £999 ee (3.2274~ 3.2281 In) 0.007 ~ 0.038 men (0.0008 ~ 0.0015 in) (0,19 am (0.0099 in) (0.030—0.070 mn (0.0012 0.0028 in) (0,25~0.95 mm (0.0088 ~ 0.0138 in} (0.35~ 0.60 mm (0.0138 0.0187 in) 0.15 0.40 mm (0.0058 ~ 0.057 in} 105mm .0H3in) 120mm (004720) 105mm 9.0413!)SERVICE SPECIFICATIONS —_ ENGINE HECHANIGAL — Thrust clearance ‘81 | 0.160~0.942 arm (0.0063 - 0.0126 in) Maximum |0:242 mm (0.0135 in) | Connecting rd bearing conor wall thickness Retocorce Maximum | 0.08 wm (0.0031 in) Rodout-oF-aligamert Maximum pex!'00 mm (3,94 in) | 0.05 nn (0.0020 in.) ‘Maximum | 0.05 mm (0.0020 in.) Connecting rod bot ckameter Minimum | 6-4 am (0.252 in) Maximum | 0.242 mm (0.0195in) ‘Maximum {0.08 mm (0.0081 in) Rodout-of-aignmont — Maximum pe/100 mm (3.9 in} | 0.05 em (0,0020.ng Fl et Maxie pext00 mm (3.84 In) } .08 im (0.0020) Bushing insise ameter ‘Connecting cod | 20.011 — 20.028 men (0.7878 —0.7883 in) Piston | 20.013 ~20.025 mm (0.7879 0.7884 in} Piston pin lametor | 20.008 20.016 mm (0.7876 —0.7060 m } Bushing ll cearance [STD Pistons Piston pin | 0.005 ~ 0.019 mm (0.0002 —0.0008 in) Maximum | 0.05 mm (0.0020 in) ‘Minimum | 4 min (0.252 in) Connecting rod thickness. 19.788 — 19.2400 (0.7791 0.7811 in) ‘Mark 1 | 3.486 ~ (490 mum (0.0886 ~ 0.0587 in) Mark 2 | 1.490 ~ 1484 mm (0.0687 ~ 0.0508 in) Mark 3 | 1.494 1.498 mm (0.0580 0.0500 in) | Connecting rod ot clearance ‘STD | 0.028 ~ 0.060 mm (0.0011 ~ 0.0024 in) Rod bat ‘Maximum pasi100 mm (3.94 in) | 0.05 mm (0.00201) Busting nse careter 120.012 ~20.021 om (0.7879-0.7682 a) Piston pin ctareter 20.004 - 20.013 rum (0.7876 ~0.7879 in} Busting oi clarence ‘STO | 0.008~ 0.011 mm (0.0002 0.0004 in) ‘tension potion STO | 6.6 ~6.7 mm {0260-0.264 In) Torus clearance ‘sD | 0.160~ 0.942 mn 0.0068 ~ 0.0126: Connecting rodthickness 19.788 ~ 19.840 mms (0.7791 ~ 0.7811 in) Reference Made | 1.482 1.488 mm (0.0888 0.0586 In) ‘Marke | 1-486 ~ 1.490 mm (0.0888 0.0887 in) ‘ark | 1.499 ~ 1.494 mm 0.0887 ~0.0888 in) Connecting rod cearance 81D | 0.028~0.082 mm (0.0011 - 0.0020 in} Piston pin x Connecting rod | 0.005 ~0.009 mm (0.0002 - 0.0008 in) tension portion STO | 6.86.7 erm (0.260-0.264in)ss-12 ENGINE: Maret Mak? Mask 1 Marke Marka Marks Maximum Maximum Maxi (0.04 0.2¢ mm (0.0018--0.0094in) 030mm (.0118in) 21490~ 2480 mm (0.0387 ~0.0876 in) (0.015 ~0.052 mm 0.0008 ~0.0013 in} 0.050 mmm (0.020 n) 47,998 ~ 48.000 mn (1.8897 — 1.9696 in) 47.996 ~ 47.898 mn (1.5896 ~ 1.8897 in) 47 994 — 47.898 mm (1.8895 — 1.8896 in) 47.992 ~ 47.994 mm (18894 — 1.8895 in) 47,980 ~47 992 mm (1.6883—1.8894n) 47988 ~ 47.800 mm (1.8892 1.889810.) 1.993 1.996 mm (0.0785 ~0.0786 in.) 1998 1.990 mu (0.0788 ~ 0.0787 in) 1.999 ~ 2.002 mm (0.0787 -0.0788in) 2.002 2.005 mm (0.0788 -0.0789 in} 48.982 —44,000 mm (1.7920 1.7328 in) (0.03 mm (0.0012in) (062 mm (0.0008 in) (0.02 mi (0.0000 in) 10.04 - 0.24 mm (0.0016 ~0.0094 in} 2.20mm (0.0118) 2.430 2.480 mm (0.0957 -0.0876 in) 0.016 0.032 mm (0.0006 -0.0013 in) 0,050 mm (0.0020 in) 47,989 — 48,000 oun (1.8807 —1.8898.n) {47.996 ~ 47.998 mm (1.8896 — 1.8697 in) 47.984 ~ 47.996 mm (1.8895 ~ 1.9898 n) 47982 — 47.994 mm (1.8894 —1.8895in} 47,990 ~ 47.992 mm (1 8888 — 1.8894 in} 47988 ~ 47.990 mm (1.8882 — 1.8868:n 1.999 ~ 1.902 mm (0.0789 - 0.0784 in 1.992 ~ 1.998 mm (0.0784 -0.0785in) 1.895 ~ 1.998 mm (0.0785 - 0.0787 In) 1.998 ~ 2.001 mm (0.0787 ~0.0788 in.) 2.00% - 2.004 mm (0.0788 ~ 0.9789 in) 44,992 ~ 48.000 min (1.779 1.7717 In} 0.03 man (0.0042 in) 0.02 mm (0.0008 in) 0.02 mm (0.0008 in$3.13 ENGINE MEGHAN Partighoned oa ator To Camera timing sprocket x Camshat WzFE 6 80 = 22-6 Ey 1 40 ave timing convoler assembly x Camshant WzFe a “80 38 22-0 54 21 0 Chain vibration damper x Cynder tock are 1 1a 8 222-0 208 208 8 Chain tensioner sippex Cynder Bock waeFe 105 109 % 222-Ge 205 209 15 Ting chain cover 1ZZ-FE: {S00 page EM-25) mm head bot A 3 189 10 10mm oad bot © 2 92 e0in-bt 10.mm toad bat chore us 119 3 12mm head bot D es 188 4 Shut (E8) 23 85 inet }222-GE:(Se0 page E25) Bat a ea 6 Bote ” 19 8 Bot 50 #2 soins Bato 20 2 e0instt sa (Eo) 9a 96 ein. Rr engine mourtingbackal x Tn chan caver W2z-FE 7 “79 38 eee 8 20 38 Driver bal tnsioner Tring cain cover Bot ware ry 108 st 22-08 100 1.020 ™ Kot 2 208 Al [rank postion sensor Tring chain cover 20 2 eink Crankset poy x Crankshat 12z-F€ 138 709 102 222-6 120 3200 a chain wensioner x Toning han cover 30 a eink Cynder head cover x Cynder head 1Zz-FE w/ Wachor 20 se ‘B0in-b wo Washor 1 13 8 2z-6E 0 00 7 No 1 verlaton pie x Gynderhoad cover ny 100 z No veatiaton pipe xia manic 222-6E 25 258 AH engine mounting nator & 330 i 370 Camshah bearing cap x Oyindor head W2EFENO 23 238 Nod 13 18 22. 125 133 Rocker No. tend No 2 shafts Cynder head 2z-E 75 7% [om conte vate housing x Gykinder head 22a 20 82 [pressive ston x Gynec had 222-6 3 130 2 [it contel va ter Grind eset 222-6 2 300 ea ytnder head Gyre ocx TELE tt 2 oo fs and} Tun90" Turn so" Jun 90° 222. 6E 1st 6 28 2% 2os| Turn 100" Tam 180° Tun 180" [Water bypass pe x Gyno ead 30 eonsoa [ECM cover Intake maniold x Cynder head zz-Fe: 1988 183 “ | 222-GE: (See page EM-£5) Botta ea 275 20 Bott a “69 4 Bot ethers w 37 25 Intake anton stay 2O2-GE 2 26 18 Exhaust manioidx Gyindor noad Ware 37 an a 50 510 37 Lowor heat insulator» Exhaust mano 1aa-Fe 12 123 8 2G 2 20a 6 ‘Upper hea! insulator x Exhaust maniold 1ZZ-FE 2 123 8 2z2-0e 20 208 8 Exhaust manos stay 127-FE 3 00 7 2u-ae 50 510 ar Engine hanger x Cylinder head @ 388 28 CH engine mounting a) 216 59 Fleer engine mounting bracket x Transaxle oo 5S a7 Flea engine mounting “Through bow | o 887 64 [Suspension member BoA 32 520 3 See page EM-00) Bott 82 580 32 Boric 113 152, 83 040 187 1600 8 Bot E 29 «00 29 at 2 530 2 PS goar x Suepension member 6 460 38 Exhaust pe 3 a0 22 citch release finer x Transeo 2 120) 2 utch release cyince bracket Bora 2 12 9 Bot 49 0 430. [A/G Compressor x Engine a 255 18 ECM box sy Bot [ECM box Shinto ore Ac dearer case Bang cap sub-assembly x Oyinder Dock 12 pokted head fst 5 76 ‘ed “ “9 Ed sa{ Tunas Tunes? Yunas* an] Tunas” Tunas Tunas ‘Hexagon nead 122-FE 185, 188 4 272-9E 8 185 13 Screw ph x subs 222-6. 3 8 2 | Connecting rod cap VZ2-FE tot 20 28 18 2nd} Tum9a" Tunao* Tum 90" 272-08 1st 3 306 2 aed |__Ten 30° Tungo" Tumsot [ou srainer 20 2 80 in tbh [Cupar baie BEIGE 30 92 Bein [Olt pan 20 92 0in.tet [Om Rter union 2 306, 2ssa5 SERVICE SPECIFICATIONS. — ENGINE MECHANICAL Engine cojant din union TERE 20 2z-8E 25 Knock sensor a vermiaton case, 22I-GE 35 7 Teint Water bypass pipe x Cylinder back Taare 80 32 ‘0in.tee 222-08 Bot 85 8 Binet Net 10 100 z a 18 36 Twn 90"$346 EMISSION CONTROL TORQUE SPECIFICATION IFICAN wm igh Pat ightoned [Carson carlson x Body nm 184Ss17 SERVICE SPECIFICATIONS — StI SFI SERVICE DATA Fuetpresaue | Fuelpressure [201 —987 KPa (21 = a5 kg, 4880 pap 20°C (68°F) [02-300 20°C @8"F) [134-1420 ‘nycton volute . 47 ~ 58 oa? (2.7 ~ 8.3.0 1n9 por 18 seconds Ditarence between aach eyinder 10.cm? (08 cuir.) or loss Ful eakage ‘One cop ots per 12 minutes Resistance a-20°C °F) | 19.8184 820°C 68°F) |221~269kn at 80C (10°F) [049-0670 ‘Omm (in) vta-e2 02-5740 20- 102k 25-59K0 at 20°C 8"F) a1 120°C (208"F) at 20°C (68°F) at 20°C 68°F) [67-440 at-20°C (°F) [10-2040 0° (a2) [4-7 120°C (68°F) |2—94n atagre (100"F) [091.980 ate0'c (140°F) [04 -0.7 kA. 180°C (178°F) {02-040 Forming 2-3ss18 SERVICE SPECICATIONS —_ SFI TORQUE SPECIFICATION Part tightaned Detvery pine x Gyinder headss19 SERVICE SPEGIGATIONS ~_cOOUNO COOLING SERVICE DATA “we remot [cee et aeecern tonnes adtaccap | Be vt opeing proovre oe [Rees ge nw eign __ [eno eons s2-aenss-20 -SSaVICESPEcinicATIONS — OOLING TORQUE SPECIFICATION Engine ondlant reservoir x Rado upper support Fen motor Fan shroud Fen Fan moteLUBRICATION SERVICE DATA 1z-FE alist speed 819,000 spm 222-6 atid speed. Ot contt valve housing 2a2-6E atic spa0d ss-21 29 Pa (0.9 kgm, 48 psi) or move 206-~599 KPa (2.055 kgm, 49-78 ps) 39.2 KPa (0.4 kyon 8.7 ps) or more 39.266 (0.4 gion? 8.7 pe oF more sie clearance ‘STD, Maximum Tip ctosrance sto Mosimum Body coarance, TD saxiron (0.025~0.075 mm (0.0010—0.0030 in) 0.18 mm (0.0059 in) 0.080 ~ 6,180 mm (0.0024 -0.0071 in) 0.85 mm (00138 in) 0.100 0,180 mn 0.0098 -0.0071 in) 0.30mn(oo118in)ss22 SERVICE SPECIFICATIONS — LUBRICATION TORQUE SPECIFICATION Pat ies wn en | express pach x Oar eck 8 199 . 3 190 A a oe 7 rr or : | wre] 37 as 7 mce| 49 2 x 20 2 wnat [7 s0 2 20in-bfIGNITION SERVICE DATA SERVICE SPECIRCATIONS — IGNITION 88-23 WE DeNSO 2EL-GE DENSO. ‘steal athot skisany eRSAN SKRORIY JERGAN 35-1400 1,060 ~ 1,645.0 eos thot 11890-2700 2.085- 3225.TORQUE SPECIFICATIONSERVICE SPECIFICATIONS. STARTING 5) STARTING SERVICE DATA T2V 14KW RV LW 90 Acrlessal 1.5 3,000 rpm oF more 158mm (0610) 10.0mm (0.304in} 176-235 (18-24%, 187-19.6N(14~204g 5.10) ~458) H.8N (2h, 26108) BAN (O9Kg, 201m 30.0 mm (9.184 ind 29.0 mm (1.412) ‘Undorcut dap 0.6 mm (0.0240) Minirum | 0.2 mm (0:008 in) Circe rorout ‘Maximum [0:08 mn (0.00201) Magnote svar Contant pla for wear Maximum |09 em (0.055 in)83-28 TORQUE SPECIFICATION———SEIWICE SPECIFICATIONS — CHARGING CHARGING SERVICE DATA 820°C (88°F) [127-128 20°C (68°F) | 125-128 12V 8A wr |27-s10 an|at-250 STD | 142-144 mm (0859-0587in) ‘Mian | 12.8 mm (0.504 in) ‘STD | 10.5mm (0.418:n) Minimum | 1.5 sun (0.050n) 192-148TORQUE SPECIFICATION _ akon et a ezine ey donne 25 aint 128 a 20 Tin. 30 25 inset 45 39insbt 48 2910-8 2 35in-bt rn 3 in-6t 2 6 580 40 580 a 238 2SERVICE SPECIFICATIONS — CLUTCH CLUTCH SERVICE DATA ‘Standeré padat ] 135.6 — 145.6 mm (5590-6 792 im) Spot pedal | 136.9 146.9 men (6.990 6.789 in.) 1.05.0 mm (0089 —0.197 in) [50-180 mm (0.197 0501 ay I 25mm (098 im) ormore 15-2. mm (0059 ~0.098 in) ‘win. Jo3mm @.012 in) Max, [0.8 mm 1.031) ‘ax. [0.1 mm (0.004 nyTORQUE SPECIFICATION im hghom a 15 135 " 12 120 2 aa 8 Fain) 12 120 2 43 Ey aan @ $00 26 ‘3 138 4 97, 35 27SERVICE SPECIFICATIONS — MANUAL TRANSAXLE (C56) SERVICE DATA 88-31 MANUAL TRANSAXLE (056) input shah cer bearing oul dametor ‘Min. [24.986 mm (0.9837) ngut ana Sd gear Jounal clamator in. [30.985 mm (12199) input shal Ah geas journal ameter in. [20.985 mm (1.1411 in Input shat Sh gear journal diameter ‘Min. [24,885 mm (0.9797 mn) ppt shat runout Max. [0.03 mm (0.003210) [Ourpct shat rater bearing jounal ameter ‘Mo. [92.965 mm (1.7906) [Output shaft 1st gear journal darote, ‘in [97.965 mm (1.4955) [Output shan 2nd gear purnal dareter Ma. [31,965 wm (1.259210) [Cutout shaft runout o.09 mr (0.00Te A) [Gonrtiewst deararce 1st (040-040 mm (0.0039 00857 im) 0.40. (0.0157 [Gosrthrust dearance 2nd (010-055 mm (0.0099 —0.0217in) (Goorthrust dearance St 955mm 0.0217in) 0.10085 mm (0.0098 — 0.0138 in.) 0.95.00 (0.0198in) (Goarthnustdearance 40 (Gear thrust darance 5h (Goar radial dearance 1s, 2nd, Grd ath and ih (KOYO mado) [Gear radial dearance 1st, 2nd, rd th and Bn (NSK mado} 0.10055 mm (0.0099--0.0217 in) 2.58.mm(0.0217in) 0.10057 mm (0.0039 -0.022¢ in) o.sTmm(o.0226in) = 0.058 ren (0.0008 = 0.0023 in} 0.058 mm (0.0028 in) fo.016 0.056 mm (.0008 - 0.0022 in) 0.056 mm (2.0022 in) No.9 gear sit fork to Na. hub steove clearance No.2 gear shit or to No.2 hub sloove clearance No.1 gear hit ork oroverse gear oarance fossmm(oors in) Synchronizer ting to goar clearance _ Yet, dthand Sh fo.75 em (0.0896 11) [ Synchronizer ring to gear clearance 3rd o.85 mm (0.0256 in) ‘Syrebronizer ng te gear clearance 2nd Drive in depth Input shat tron ol sat Input haf ont bearing “Tanemission case busting ‘Tanemiecion caso oil sal (Shit and aoloct vor shaft) ‘Trangrrission case ol sel (Oierandal casa sido) ‘Yansase case ot seal ‘Select ner lover satid eng ola No.7 shit inner taver shored sing pn fo 7omm 0.0276 in} 18:8 = 02 mm (0622 = 0.008in) Jo-0.3 mm 0-0.082in} o.80~1.30 mm (0.09150 0512 In) 10.0. 03mm (0.398 = 0.012in) 2.9 = 0.3 mm (0380 + 0.012in) 1.9 £ 0.3m (0075 = 0012in} Jo + 05mm (0+ 0.020in) Jo + 05mm (0x 0.020in} 35 = 0.5 om (0198 = 0.020%n, No.2 Rion lve sorted sping gloss-32 svi SPECIFICATIONS — MANUAL TRANSAXLE (C59) input shat snap ring hicks ‘No. 2 ebtch hub Marko | 20 mm (0.0006 ny Mark 1 | 2238 mm (0.0929:ng Mori2 | 2.42 vm (0.0958in) ata | 2468 mm (0.0978 In} Marka | 2554:mm (01000 in) Mark 5 | 2.60 mn (0.1024 in) Paar easel ball boating Mark A | 2.20 mm (0.0902 In) Mark & | 238 mm (0.0828in) Mark ¢ | 2.41 mn (0.0949 in.) Mark 0 | 247 mm (0.0972. Marc | 253 mm (0.0096 in) Mark F | 2.59 mm (0.1020 in.) ipa sat snap ring thickness No. toh hu Mark A | 2.60 mum (0.0984 in.) Mark 8 } 2.56 mm (0.1008 in.) Mark ¢ | 262-mm (0.1031 4) Mark 0 | 2.68 mm (0.10850) Mark € | 2:74 mm (0.1079 0.) Mark F | 260 mm (0.1102) Front bearing inner race ‘Mack 7 | 1.85 men (0.0728 In) ‘a 8 | 1.90 mm (0.0748 0) ‘Mat + | 1.98 mm (0.0788 0.) Mark 2 | 200 mm (0.0787 in) Mark 3 | 2.05 mm (0.0807 in) Marka | 2.10 mm (0.0827 in) Mark | 215 mm (0.0848 in) Mak 6 | 2.20 mm (0.0868: (No, 9 dutch hub ‘Mark & {2.26 mm (0:0988:n.) ‘Mak | 2:31 mm (0.0008 in.) ‘Mark ¢ | 2.37 mm (0.0803in.) Mark 0 | 2-49 mm (0.0957 in.) ‘Mask E | 2.49 enm{0.0980 in.) ‘Mask F | 2.88 mm (0.1004 in} Mark [2.64 mm (0.1028in) Dicer tapered lr bearing preload (a starting)(For use wth SST) ‘Now boating | 0. im(@~ 1Bkghem, 68~ 18.910, 21) eused bearing {0.8 -1.0Nm (5 —10 kate, A3~B.7 aI) Deronda pion to ide gear backiaah (0.05 em — 0.20 mm (0.0020 — 0.0078 in) Diferonia ie gear fst washer Uickness (0.95 me (0.03741) 1.00 rom (0.0994 in.) 1.05:nmm (0.0413in.) 1.10.mm (0.0488n) 1.18 mm (0.0453n.) 4.20 mm (0.94720)5 SPECIFICATION MANUAL iteronal tapered olor bearing aductng shim thickrass Mask AA Mark 88 Mark oo Mark OD Mark EE Mark FF Mak 68 Mark HH Mark JJ Mare kK Maru Masi MM Mark NN Mark PP Marka Mark AR ark TT Mark UU 2.10.mm (0.0827 in) 2.35 mm (0.0846 in) 12.20 mm (0.0866 in) 225 mm (0.0888 in) 230 mn (0.0608 in} }225 mm 0.092610.) 2.40 mm (0.0848 in) 2.45 mm (0.0968) 2.50 mm (0.0964 in.) 2.55 mm (0.1004 In) 2.60 me (0.1024 in) 285 mm (0.1068) 270 mm (0.1063 6.) 2.75.mm (0.10830) 2a0mm (0.11020) 285mm (0.1122In) 2.90mm (0.1142in} 2.95mm (0.1161 in} 3.0mm (0.1181 in)$534 SERVICE SPECIFICATIONS ~_ MANUAL TRANSAXLE (255) TORQUE SPECIFICATION = Panvationed we eee ea 70 7 fhm rr 30 i e9 70 Stinsbr 69 70 tint eal 8 785 8 rtf 2 ° pal 12 ° por] 49 2 aint iach reas ex Tansada 2 A : 7 a8 2 arse x Ere on rma a) ee eo @ ans x Engine (For ego) eal ar 0 rs Se page n-9 Po oes = 2 No. nN. 2 erga hengesettck = 7 2 Engpo tot meting hace Treat © 610 “ Engine mourting tact x Engine inf mourn reltr 0 20 = Cxygen sores Font exhaust poe 4 0 s Fronterhast pe a He @ | goer assent x Suepensen cosemonber 6 a8 3 Engine rear mounting insviator x Engine roar mounting bracket # 0 24 Engh ea: mourn bracket Taree 4 50 a, Passenger sag aseby 20 204 15 ng sree 57 2 a6 1s Seeing wnt ck at BN ato ra shaiacrasseriy x Body 2 0 3 St cable tae x Body rr @ Bin Shae select cor cable act s 2 “inst Fer adie ge 2 100 28 ei eped ent rT 15 ¢ actu bt th 2 a1 a0 onto cil brace Tareade cae 25 0 8 [onl at astenbiy 2 3 Seleciog bleak aseonty x Tenorio ata Ts 0 ‘2 Lever kin sett 2 20 ® Nevarieon cate x Tanaris eas one ‘2 85 7% Locka assent (Shi ond eect ever ahaa) 2 xe ee ont ha cover x Tasison cape a 200 rn th tn goa tock nt 18 700 a _ Nef No.2 and No 9 ger Sn ove obo? mn 10 2 Rea bearing reine Vanemison cam zr 0 20 Revere ior goa shah ck ot. 20 so | a [ Seat ew tg 2 280 8 Locka asomby everest ido wt 00 2 Trataneton case Tanai case 28 ‘xo 22SERVICE SPECIFICATIONS —_ MANUAL TRANSAXLE (036) ss-35 13 2 Output akan tron beavng lock ple sel bot Tronsanie case racoter x Transeo caso Sow gg (Revere rec pa) [itoonda case x Ring gear a,33-36 _——______BBBIVIGE SPECIFICATIONS _=_MANUALTRANGAXLE (060) 00 MANUAL TRANSAXLE (C60) SERVICE DATA nut shalt oller bearing journal demetor Input halt rd goar journal diameter 24,985 mm (09897 in) 30.985 mm (1.210910) 28.985 mem (14411 In) 24,006 mm (0.0797) 21.901 mm (0.8658 in) 0.09 mm(0.0012n) | $2.906 mm (1.2966 in) 37.985 mm (4955 fn Quint ena runout ‘Max. [0.08 rm (0.0012 in) [Gear tinustcesrance Ist ‘S10 | 010-040 mm (0.0089 0.0187 in) Max. | 0:40 mm (0.0187 in) (Goarthrst clearence 2d ‘SID | 0.10085 mmm (0.0050 -0.0217 In) Mas. [0:58 rn (0.0217 in [Goarthnustcearanco Sed ‘STD | 0.10 0:35 mm (0.0089 ~0.0128 In) Max. | 0:35 mm (0.0198) [Goarthnstcearance 4th ‘S10 | 0.10055 mm (0.0069 -0.0017 in) Mas. | 0:58 mm (0.0217in) [Geartwstclearance in ‘STD | 0.10062 mm (0.0000 — 0.0248 In) Max. | 0.62. (0.0248 in.) [Goartheustclearance 6th ‘STD | 0.10 0.60 mm (0.0089 -0.0235 Max. | 0:60 mm (00296 in.) [oar radatclaarance st, Grd, Grd and ath (KOYO made) ‘STD ] 0.15 -0.58 mm (.0006 0.00251) ‘Mas. | 0.088 mm (0.0028 in) (Gor redial clearance ta, 2nd, Srdand 4tn (NK made) ‘STD | 0.018—0.086 mm (0.0006-0.0022 1) ‘Mex. | 0.086 rm (0.0022 in) [Gear rata clearance ‘STD | 0.015 0.056 mm (0.0006 0.000210) Max. | 0.086 mm (0.0022 inp (Goer radial clearence 6 '810 [0.009 —0.080 mim (0.0008—0.0020 in) | 0.080 mm (0.0020 in) No.8 gear srk to No.3 tub sleeve clearance 0.89 mma (0.095 in) No.2 gear sf fon to No. 2 hub sleeve clearance | 0.85 mm (0.014 in) Max, Nas. Max. No. gear efoto reverse gear clearance, Max. | 0:38 mm (0.01410) Mi. Mi. Min rorizer igo gear clomance tet 2h, 5h and 6th 3 | 07 mm (0.02980) Synchronizer ring to gear eerance 20 0.65 mm (0.025610) Sypehrorzer rng to gear dearence 2nd [070mm (0.0276in.) Drive in pth Input shat ont ol sat 15.8 0.2mm (0822 = 0.008in) {pe hat ont bearing }0-08 mm @-00%zin ‘Transmission case busting 0.80 = 1.30 mm (0.0315 0.0512 in} ‘Yranemisson case ol seal (Shit and selct lover shat side) 10.0 + 0.3mm (0.954 + 0012in) ‘No.1 and No.2 shitiner lever slotted spring pin }0 = 0.5 mm (0 = 0.020in,) ‘Teansmisson case ol eal (Oierentl case side) 9.9 = 0.3 mm (0.390 = 0.022 in) ‘Teansste caso ol seal 19 ¢ 0.3mm (0075 = 0.0129) Diterenal side goar baccash 0.05 - 0:20 om (0.0020 — 0.007983-37 SERVICE SPECIFICATIONS, UAL TRANSAYLE (C60) ‘Diterortial tapered roller boaring reload (a starting) (For use wan SST) Input shai snap rng Wickes No. Dehn hub ‘No.3 ach hub Inu shaft coer ral bal bearing ‘put shat rear racial boating Now boating eusod bearing | Marko Mark 1 Mark2 Mare 3 Mare Marks Mask A Mark B Mase Marko Mare Maer Mark Mark Marks Mak Mark Mark Maid Marke Mark Marie A Mark B Mark Marko Mark E Mak Man wake Marks Mak K Mase Maro 0.95 mm (0.0974n) 1.00 mm (0.0394 i} 1.05 mm (0.0618 in) 1.10:mm (0.0693 0} 118mm 0.0453) 4.20mm (0.0472 in} 0.8-1.6Nm(8~16kgtem, 69~ 199in-h) JoS—1. 0m (S— 10hghem, 43-87 ib) 20 mn (0.0908 in.) 2.96 mm (0.0820) 2.42.mm(0.0963in.) 248mm (0.0976in) 254 mm (0.1000%n.) 2.80 mm (0.1024in) 1.75eum (0.0880i0.) 1.90mm (0.0708in.) 4.85 men (0.07280) 4.30 mm (0.07480) 1.85 mm {0.0768in.) 2.00mm (0.0787 in) 2.05 ern 0.0807 in.) 2.20mmm (0.0827 in) 2.15 mm (0.0846 i.) 2.29 mm 0.0902In) 2.35 mm (0.0925in) 21 mm (0.0949 in) 12.47 mm (0.097240) 2.53 mm (0.0986) 2.59 mm 0.10201) 1.70mm (0.0889 in) 1.75 mmm (0.0888 1) 1.80 men (0.6708 in) 1.85 mm (0.0728 in) 190mm (0.0748 in) 1.95 mm (0.07680) 200 mm (0.0787 in} 2.05 mm (0.0807 in.) 2.10 mm (0.0827) 2.15 mm(00846in,) 2.20 em 0,0888in) 2.25 om (0.0968 i,38-38 ———_BBIVIG S SPECIEICATIONS._—_MANUAL TRANSAXLE (Ggg) urge shaft sap ring thickens (No.1 etch hb Mark A | 2.50.mm (0.08840) Mark | 2.58.mm (0.10080) ec | 262 mm (0.1031 Fn.) Mark | 2.68 men (0.1055in.) Mark € | 2:74 (0.1078) Mark F | 220 men (0.110216) Front beating ier race Mark? | {85m (0.0728in) Mark8 | 190mm (0.0748in.) Maret | 1.95 (0.0788in) Mark2 | 200mm (0.0787in,) Mark | 2.08 me (0.0807 in) Marca | 2.10. (0.0827 in) Mans |2.45.em(0.0846in) Mars | 220mm (0.0888:n} (Outpt shat rer racl bal bearing ‘Marke | 231 mm (0.0908 .) Mark ¢ | 237 mm (0.0889 ir) Mark 0 | 2.49 en 0.0987 a) Mark | 2.49 em (0.0960) Mark F | 2.65 mm (0.1004 in.) Mare |261 mm (0.1028ie.) Mask H | 2.67 mm (0.1081 i.) Mark | 2:73 mm (0.1078in,} ‘Mart | 2.78 ene (0.1088. } Mask | 2.85 mm (0.1122) Mark M | 2.91 men (0.11460 Déterertal tapered caller bearing adjusting ate thickness Mark AA | 2.10 me (0.0827 in.) Mark 88 | 2.6 mm (0.0848in.) Marke GC | 2:20 mm (0.0666 in) Mark 00 | 2:28 mn (0.0688 in.) Mark €€ | 20 mm (0.0806 in} Mark FF | 2.35 mm (0.0825in) Mark G6 | 240 mm 0.0846 n.) Mark HH | 2.45 mm (0.0968 in.) Mark JJ | 250 me (0.0684 in.) Mask KX | 286 mm (0.5004 in) Mark Ut | 260 ra 0.1024 in) ‘Mark Mis | 2.85 mm (0.10830) Mast NW | 2.70 ram (0.1069 in.) Mark PP | 2.78 mm (0.1089 in.) (ark 00 | 280 com (0.11020) Mark RR | 2.85 am (0.1122in-) Mark $8 | 2.90.mm(0,1142in) Mask TT | 2.98 mm(0.1161 In) Aare wy | 9.00 mr (0.1181 in)TORQUE SPECIFICATION = L Part tightened Nm kghcm ed Ne. 2 indo head cover Te. | e@n-ee [actor ever ct bot 49 2 ‘sinh ae = 2 —| 8 a af eae =e =|} — 2 amavis =} = = : ama Bs ® | ete Sate chara $ 3 ; ae 3 = 3 Se aaa z = 3 ees zat — = 2 ao sale = 5 [neta rgetargorsmse 2% oy FI _Enging lott mounting bracket x Transaxle 60 610 46 ee a 3 a : = 3 mam : = 3 ee 3 = 2 as t+ = : Eigen ovning octets Taam rn wf enon a = 7 eee : = 3 Steering wheel lock nut w 350 tC 25 ee = = : me = 2 ee s eT ee : 5 : ae = : : = 3 = 3 See 2 = 3 — : = : | Selecting betlorank assembty x Transmission case 28 280 18 — 5 +4 Se mae : = $ Se 2 = 3 (ee eae 2+ 2 2 Se 2 = z faa etme 2 2 3 Fiear beanng retainer x Transmission ce: 27 280 20 Reverse icter gear shatt lock bot 29 300. 22 et += a 3Trensinie cose recohar x Transavie case [Os cab pps gear x Diforential case8S-41 SERVICE SPECIFIOATIONS —_AUTOMATIC TRANSAXLE (U240 AUTOMATIC TRANSAXLE (U240E) SERVICE DATA Line procsura (Whoel locks) Engine ising D postion | 272 412 KPa (28 4.2 kalo, 84 ~59 psi) R position | 672— 742 KPa (8.87.6 kglon?, 97 — 107 psp AT stall (Torco valve fly 29a) D postion | 91 - 1,091 kPa (2.5~ 10.5 kglom, 184 ~ 149 pi) Fiposion | 1,788 ~ 1,968 wha (18.0 20.1 kglem?, 256 284 pt) Engine sal revontion D position | 2220~2:520 1m rime ag N-¥D positon [eas thar | 2 seconds N+ R postion | Lees than 1.5 soconds Engine ide speed (GOFF) positon | 650 + 50 5m Drive plata runout ‘Max. [020 mm (0.0078 in» Torque converter ch runout ‘Max. $0.30 mm (0.0118in) Torque convoter clutch installation citance Mora tan 12.78 a (0.5000 i.) Deterental ol seal rive in dope tn sie [2.7 05 mm (0.106 £ 0.020) Pi side [0 + 05am @ = 0.020in) shin scheaue postion (Tht vavotuly opened) 442 [60-67 kann (37 ~ 42 mph) 2-93 | 112-123 4evm (70— 76 meh) 3-94 | 179101 keh (144 ~ 119 mph) 4-93 | 173-186 kvm (107 ~ 115 mph) 8-42 | 105 ~ 116 kwh (65-72. mph) 2-51 |44—504eum 27~31 mph (Thetis valve tly dosed) 8-24 | 40-48 wh (25~ 26 mph) 493 | 14— 195mm @~ 12mp0) 2 potion (Throne vate tuty opened) 1-42 | 60—67 km (97 ~ 42 mgh) 9-92 | 112-128 kwh 70-76 mph 2-91 | 44-80 kmh (27-3 mph) ‘postion (Throte vate hal opened) 9-92 | 112-128 4mvh 70-76 mpd) 2 +1 [52—S0 mh (92-28 mph) Lockup pire ‘Tate vai opening 5% ‘rd gear Lock-up ON | 220294 kh (187 — 145 mph Lock-up OFF | 220 ~ 258 kruh (137 ~ 145 mph) 0 gear Look-up ON | 7581 kav (47 — 50 mph) Lockcup OFF [56-71 kmh {40 - 44 mph)ss-42 SERVICE SPECIFICATIONS — AUTOMATIC TRANSAXLE (U240F) TORQUE SPECIFICATION Panightered aon ‘ibe Veticle speed sonsor x Transmie 5 310. input turbine spoed sensor x Trensaxte 45 3 (Counter gear speea congor x Traneae " 315 e [ATE temperature soneor x Trarsade 68 o Bein. Olpan x Transaxle 0. 690. tbt [Conot cable x Gontro shaft 20 2 Control shaf x Parner poson atch 130 3 Partnetal postion ewach x Transaxle Bat 3a 35 Binet Na 89 20 Sint Sit colenid vale = Valve body 2mm O47 inj 66 o ‘Bint asmm(t77in) 10 8 Valve body x Transaxle 10 @ [Ot sralnerx Valo body, Orin plo x On pan Steorng wre sot ns 4 350) 25 From passenger aitog assomby x raument panel reinforcement 20 204, 15 Foor shi assembly x Body 120 3 Hood set bot | 130 3 No. 2 eyinder head cover 7 ein. tor ECM case set bot 0 Stinutoe ECM sat bo 58 70 ore ECM octet set bot 18 186 6 [OM bracket set aut 12 20 3 agit secon 56 bo 49 0 Sin.tbe [Ground cable x Transade 18 185 13 [Starter x Transaxle ‘7 38 2 brain plug x Merona 54 550) 2 Sabazer bar nk x Shock absorber “ 450. 32 Lower suspension arm x Lower balfont 132 1.480 105 rive shalt tock nt 216 2200 159 Steering knee x Th od end 8 $20 3% Drive shaft bearing ook bot e 0 2 Power steerag gear assembly set bot 9 ed [Contr member x Booy 8 386 28 | Contr member x Engine kort mounting 52 830 38, Suspension mernber x Body Froct si 13 1182 8 Rar aio 137, 11801 116 Engine rear mourainginoulaor x Engin rear maurting bracket o 250 a Engine roar mounting insulator x Suepersion member 52 550 28, Engine banger got bot 38 387 2 Engine ll mourlag x Engine ft mounting bracket 80 16 2 Targus converter cui x Drive late a my 3 Transaxle housing x Eagie took ‘See page AX20 Deve plate x Crankshat ed 37 55,SERVICE SPECIFICATIONS — AUTOMATIC TRANSAXLE (us4ie) AUTOMATIC TRANSAXLE (U341E) SERVICE DATA Line pressure (Wit ckod) Engine ing D positon | 372-407 kPa (38-42 kgltem?, 54 ~60 psi) postion | 588 - 683 KPa (6.0~ 7. kgHlen?, 85 — 100 ps) ‘at stall (Thro valve fly oponad) D postion | 1,153 ~1,264 kPa (11.6— 12.9 kglem®, 168-183 pay position | 1,589 ~ 1.781 KPa (162 ~ 18.0 halen? 290 258 pid Engine stat rovounlon ‘D and A postions | 2,050 = 200 mm N+ postion | Less than 1.2 seconds N—>Apoation | Lees than 1.8 seconds Engine ite =peos postion | 750 + 50 pe rive pate runout Max. [020mm 0.007810.) Yorqua converter runout ‘Max. [0:30mm 0.0118in) Tore convertor ineaation datos More than 20.7 mm (0.8160) Dilereria oi sea vo ta depth LH side [27 = 0.5 mm (0.108 = 0.020 In} FH side |= 05 em (0 + 0.0201n,) Shit schedule D position (Title valve ty opened) 1-42 | 49—35 mm (0 — 94 mpi) 2-43 | 92~ 102 kmh (67-63. mph) 3-400 | 148.— 160 km (02-99 mph) 000-93 | 143-155 krvn (@9 -95 mon) 3-92 | 86-95 bmn (59 -59™mph) 28 |42— 47 heh 28-29 mph (Trele vate uly dosed) 8-4 GD | 40 ~28 kvm (28-28 mon) (OD +3 f 25 —91 km (16-19 mph (Treatie valve tty epened) 1-42 |49~ 55 tov (90-34 mph) 9-42 | 69~ 20 kava (55-62 mph) 2-41 |42~ 47 km (2629 mph ‘Throte valve hy opened) 9-42 | 29-S9 Km (85-62 mph) 2-94 | 48 —51 th (29-32 phy "Thote valve opering 5% Look-up ON | 57 ~63 km (35 ~30 mph) Loceup OFF | 55 ~ 60 km (94 ~37 mph) Lock-up ON }51 — 58 hh (32 ~35 mph) Lock-up OFF | 48. 56 km (20 34 mpssas -_amqurerspansass TORQUE SPECIFICATION ~ Pant tightened Nm kghem ‘tor ia nae sees [Sera te is =| ene propa one n m ; Satan 2 oo] oem Senaoomas n ie ; Seana nae aa = "2 : Sncntoanonaeies oats S mats 3 Smacao Ta smear) 5 genteel ie aie 1 m7 : iat x ts : Sara 8 = = or ‘ = = Sinan Son ai eam 7 = z foc ‘ a ; fae z = : fashion tm a eaten 33 eae sores 3 eee aaa : = z saleetaaa nl iS i fanaa 3 eae anceeeces ‘ = = soso z 7 a rin pug x iterontad | Stabizer bar nk x Shock abeorbor Lower suspension arm x Lower ballot Engine roar mouating insulator x Engine reas mounting bracket 290 ee Engine ear mounting insulator x Suspension member Ee 530, 38 Engine hanger set bot 3% 27 28 Engine jot mourn x Engine ht mourting bracket 2 ae 39 FRorgue convertor cht x Ove pate 8 250 18 Transaoie housing» Engine Bock eo page AX20 Drive plate x Grarkshat 2 00 EYss-45 SERVICE SPEGFICATIONS — SUSPENSION AND AXLE SERVICE DATA [ize engne ocite accor ron 20803 2 emt ope) es cotter manera seers | P20S/S5A16 67V Front, rear 220 kPa (2.2 kgtiem?, 31 pei) asonnsery atcha er HOI, Press root | eo mma) tore [zen atm) Tear SE FRG row | woamerase Tocrs|s29mn oon) Twos msa0n16 reo" |tcoempson) foe | as esis eae sesoons proean | an 24 c047 207 POSISSRIS, P2OSISSAIS | ~0°25" + 45°(-0.42" + 0.75") ‘2OS/SOR16 | ~0°29' + 45° (-0.48" = 0.78") fester | 075) on ea sesuons praseons [or «a se" <0759 aosums ramsans | Por as oe 078) a siseane |For sas os sos) alignment rat on err (75) ore Sen aan seotoue reson | oe = 8.8 £078) ocenigransamis | oe Sas (our 2075) asus | aie seta’ 2000) rig tare [ 40759 oan oem taal = "207-02 200 00m) pace entnghstonen| Sse St eras age aceon Paseo le ant | 00 gas 227 conse etrmes [aren aay esc raeanns vested [sae = 7 (O77 227) uso wha tow |e ee) axeccnis einen so 2°80" 227) ls ie wos en |S56 838) — hie er simmen— Posgaar aif fs 282 Span e TOD teencossreananemtstcns [prone Sn Mes | 05> | has ota vin [007 036SERVICE SPECIFICATIONS —_ SUSPENSION AND AXLE. Deve a standard Hogth IEEE) 251.0 = 5.0mm (98508 0.197 in) 1565.9 + 5.0mm (22.279 = 0.197 in} 455 2 6.0 mm (03.287 = 0.197 in) 868.7 = 50mm 22.198 0.197 in) 1.0= 49m (10—50 kghom, 8.7 — 43 nb) 0.05~1.0Nm (0.5—I0Kgtem, 04 ~ 87 n.1bN) $22-FE (WM) and 222-08 Lower blot ting txaue, ‘Subtizer bat lnk bal ine tung rorque “1: Front measuring point Measure the distance from the ground to the center of the front side lower suspension arm mounting bolt. “2: Rear measuring point ‘Measure the distance from the ground to the center of the rear side lower suspension arm suspension mem- ber side set bolt.ss47 SERVICE SPECIFICATIONS SUSPENSION AND ARLE TORQUE SPECIFICATION - Par iene iim wen ca From ace a 7s imo % Tier end ocka 7 7 Seng ici x Soo sant 155 ‘ato rm teeing tm Bat ate 7 180 7 Senin tle Te od or e 20 8 as xa ze 2200 =] {et al Lowe Speen om 12 1480 105 Ler ba ont x Sierra ue 108 1280 a Set kx Dat or 83 & Pine ABS ped sess 80 @ insbe FRONT ORWE SHAFT ote ha cnt ening cave ocboR we we z FRONT SUSPENSION Sumpension suppor 805) = 700 2 suaperio snpon «Pen @ a u Pete hove x Steabeoror @ 2 ra ABS eps eno vir hues Shad nor rm @ Tne Lew eupeeon am stb 7 is 701 FS easton 6 0 3B 98 a 2 agin Upper suspension arn x Suspension member 7 755 35 Lower suspension arm x Suspension member 7% 755 [Lower suspension ann beacket 9t bot 115 173 6Lower evaponsion wm bracket x Lower suspension a wee Sapa ex bracket set bolt 14ss49 SERVICE SPECIFICATIONS — BRAKE. BRAKE SERVICE DATA cake peda reserve stance at 490 N (50 Ka, 110.2160) Fronl brake pad thickness (1Z2-FE engine) on 190.8 149.8 nm (6.504 5.6980) 1= 8mm (004-0.24in) More than 86 mm (8.38 in) [omm (06) 11.0 mm (0.4890) Front brace pad Wicknoss (222-GE nga) Font brake ped thickness Front brake dsc riccooes ‘sD Meir Front brake dsc hiccrens STO | 25.0 am (0.984'n, Metmunn 14.8 mm (0.45316) 5.0mm (0.08940) 23.0 mm (0.9060) 2.05 rom (0.0020in) 0.0mm (0394in} 0.18 mm 0.00591n) 173.0 mn (6811 in) 174.0 m0 (6.8500) 2000 mm (7.874) 201.0mm (7.9181) 4.0 nm (0.157 im) Rear baka dum Yo show desrance [oom (0028) Crum brake shoe wring rickness ‘Minimum [1.0 men (0.038) [20mm @079in) 1.0mm (0.099 0) BB lis, Less tha. 0.95 nu (0.0198 in)$3-60 RAKE TORQUE SPECIFICATION )scsi SERVICE SPECIFICATIONS — STEERING STEERING SERVICE DATA ‘Maximum | 5 im (020 0) 7,385 KPa (75 kgm, 1,087 95) [o5N-m (65tatom, $810) [0.27 Nem (28 kate, 2.4 0-1) or lass ‘Vane pump shat and troat housing busting ol clearance ‘ST | 0.021 ~0.043 mm 0.0008—0.0017 in) Maxiooum | 0.07 mm (0.0028 in} Minin | 76mm (0-299 in) ‘Wena [1.406 mt (0.0559 1) ‘Vane pate loth Mirage | 1,908 rn (0.4722 i.) ‘Vane palo and vano pump rotor groove clearance, Maximum [6.03 mm (0.0012in) 12,001 — 12.003 rm (0.47248 ~ 0.47256 in) 11.999 —12.001 mm (0.47240 -047288 in) 11.997 ~14.99mm (0.47232 - 0.472401) 17'395 ~ 15.997 men (047224047202 in) 11.959 — 11.908 mun (0.47216 0.47228.) 36.8 mm 409i} ‘Steering rack runout ‘Maximum [1 (00041) Tots preload Tuning [0.9 13m (9 19gter, 80 — 115 8)$862 pect TORQUE SPECIFICATION ~ Part tahtened Nm L totem ‘fb Tac ereena cou cesta it Sees No.2 tierreokion m s one Ta owing expat kn abe ts 1s w No. 2twredate df easel a gh aon & 0 Gok sony sett art a 210 6 No. 2ireamrecito Sak ewer» erred exeoon 6 60 2 Seong wel so 4 0 2 Sowing Weel gad sets Cero) a © Tene POWER STEERNG VANE PUM Fro hese lew asia Zz 7 % —+ # rr % a 20 s @ 720 a inst bak ve 3 PS ana pup ase et | a0 2 Pressure fed bo amp eet 78 © nw reese feed ube xP ware pre asiy wa) wae 763) POWER STEERING GEAR B Besroa ge 2 ack ning oe % Flack ond x Steering rack 830 (50) 46 (61) Terodend kat 7 Torn pressure bes Ras a 0 256) a0 peer unt ac tok @ Exe er mont acl Eager our alo oe Ingres sion x Cont va ht 2 1 ou aerby ttt = Fant supershn monty wiper npewinarexfane Gon n Bot 16 core] oe 90 2a Crghe ont noon neds Fens naekn mente A 30 rn Eng vn mot mason weperion ember 2 0 8 Danie bk eatt “ rm % Lower uspenson arm x Love blot a2 180 168 Ergo ood Hinge rm 30 : “uke dunp 78 © enti eso ond an un aes PS pw stab 3 aso) 27139) Tiere x Stag ews s 0 ss _) (): For use without SSTSERVICE SPECIFICATIONS —_ SUPPLEMENTAL RESTAAINT SYSTEM ) SUPPLEMENTAL RESTRAINT SYSTEM TORQUE SPECIFICATION ‘ate ror 350 a 0 ain. 205 18 “0 2 210) 15 35 z | 26 15 205; 15 206, 15 ra Tine83-44 _—___________SEAIVICE SeciFIGATIONS - soDveLecTmIga, BODY ELECTRICAL SERVICE DATA = ‘Alowablevange (mph) 19-22 2 395-895 20 2085, 100 1001055 20 1201255 ‘Alowabie range (emp 2 18-23 0 40-8 2 20-645 a 20-05 100 300-105, 120-1255 AGHOMETER (ON-VEHICLEY DO 19.5 V 25°C at(77 °F} Saha 700 1.000 2.000 3,000 4800 5,200 6.000) 51800 6 200 7,000 6,800 — 7.200 [FUEL SENDER GAUGE ‘oat postion wm (hn, Resistance (0) Apron. 7658 (2:99) Approx 80) VE: opton. 17.20.68) Aopror, 916 E: Approx, 508 (2.00) 4 Approx. 110.0 [ENGINE COOLANT TEMPERATURE SENDER GAUGE (Resletance) Terperav'e “CF, oaitence (a) 501220) 160~240 120(248.0) 170212,SERVICE SPECIFICATIONS —_woDY BODY TORQUE SPECIFICATION “ Par igioned fm fem ero —— = — “ en ff Front bumper enforcement Body es rm [REAR BUMPER. ~ [ ~ = er burp riforoerent x Body 2 20 1 Hood tinge x Hood 3 106 2 Hood ek xB a8 70 Sine 30 82 7rinaot ‘Outs rear view rior» Door panel 3 8 aint ‘Upper window stop x Door panel 1 45 a esis “inch Taint incbt Sint Bint ‘sink ain. tot Bint a]: [B18 (Blalalslalelalale|s Door handle x Door pane 54 5 ain. ih Door tinge x Door panel w 15 é ‘oor hinge x Body 19 138 14 ‘Door lock ster x Body " 15, 8 BACK DOOA STAY = — = Back door stay x Body 23. 6 ain. Back door stay x Door panel 20 [FRONT WIPER AND WASHER. Wiper mor x Wiper link assem 6 ‘Wiper mator and rk assomy x Body 54 a ein tr Wiper arm x Wipor eetoranaliok asgembiy % 38 23 [REAR WIPER AND WASHER = = = ‘Rar wiper motor x Doot panel 3a, 6 ener ‘Rear wiper arm x Rr wiper motor a % Bint [ROOF HEADLINING ~ = = Diva goa x Siking rat assembly 34 8 450 bt40 in-tot 13 on Bss-s7 AIR CONDITIONING SERVICE DATA NOTTIONING. [480 = $09 (15.17 = 10602) [650-50 am /a60 + 50 pn [0.45 2 0:19 mm (0.016 = 0.004)93-68 SERVICE SPECIRCATIONS —__AIR CONDITIONING TORQUE SPECIFICATION = Petarened wa ‘atom ee Seton ox Goranson 2 100 7 Distarge hose x Compress 100 z [Discharge hase x Condenser [Compretor x Engine [ep tite x Condenser 5a a Baw Erie x Expansion abe 34 3 bint Presue evi igi ube 7 100 7 Proceue phe x omestor 7a 135 2 0 100 7, 7 100 7 0 [7DIAGNOSTICS ENGINE ..... HOW TO PROCEED WITH ‘TROUBLESHOOTING ..... CUSTOMER PROBLEM ANALYSIS CHECK PRE-CHECK DIAGNOSTIC TROUBLE CODE CHART PAATS LOCATION ‘TERMINALS OF ECM ..... PROBLEM SYMPTOMS TABLE CIRCUIT INSPECTION . AUTOMATIC TRANSAXLE (U240E) ».s.0. HOW TO PROCEED WITH TROUBLESHOOTING ......0.-..s0sessse05 ‘CUSTOMER PROBLEM ANALYSIS CHECK . PRE-CHECK DIAGNOSTIC TROUBLE CODE CHART PARTS LOCATION ‘TERMINALS OF ECM - PROBLEM SYMPTOMS TABLE «so... CIRCUIT INSPECTION... AUTOMATIC TRANSAXLE (US41E) ...-. HOW TO PROCEED WITH ‘TROUBLESHOOTING (CUSTOMER PROBLEM ANALYSIS CHECK PRE-CHECK .. DIAGNOSTIC TROUBLE CODE CHART .. PARTS LOCATION - TERMINALS OF ECM «2... PROBLEM SYMPTOMS TABLE... GIRGUIT INSPECTION ..... ANTI-LOCK BRAKE SYSTEM WITH ELECTRONIC BRAKE FORCE DISTRIBUTION (EBD) HOW TO PROCEED WITH TROUBLESHOOTING .. ‘CUSTOMER PROBLEM ANALYSIS CHECK .. PRE-CHECK DIAGNOSTIC TROUBLE CODE CHART ... PARTS LOCATION wee TEAMINALS OF ECU ... PROBLEM SYMPTOMS TABLE .. CIRCUIT INSPECTION... SUPPLEMENTAL RESTRAINT SYSTEM HOW To PROCEED WiTH ‘TROUBLESHOOTING .. ont pra ors er Deis bF20 Dree Dias r55 piss Di-t58 b-s7 Dies Di69 L170 Dii72 DH75 Di-218 prete Dr2t9 b220 Dr2st bp2s2 pi233 p23 Dres8 piers Deere 01-276 bL-276 Dr-280 Dhaai Di-2se Di-2e4 285 Di-324 CUSTOMER PROBLEM ANALYSIS CHECK ... I-25 PRE-CHEGK . sectieeseserieseses DIZ DIAGNOSTIC TROUBLE CODE CHART or332 PARTS LOCATION ..... 01-395 TERMINALS OF ECU .. + Dha6 PROBLEM SYMPTOMS TABLE .........-.... 01-338 CIRCUIT INSPECTION... 01-339 CRUISE CONTROL SYSTEM ............. D483 HOW TO PROCEED WITH ‘TROUBLESHOOTING .... Dkae3 CUSTOMER PROBLEM ANALYSIS CHECK ... DI-4e4 PRE-CHECK . : - DhMdes: DIAGNOSTIC TROUBLE CODE CHART... Di-a80 PARTS LOCATION . i491 TERMINALS OF ECU . or4a2 PROBLEM SYMPTOMS TABLE... Orage ‘CIRCUIT INSPECTION oe oL-496 BODY CONTROL SYSTEM ........ Di-s35 HOW To PROCEED WITH ‘TROUBLESHOOTING ....... +. 01-636 ‘CUSTOMER PROBLEM ANALYSIS CHECK ... 01-536 PARTS LOCATION coceseeseees DESOT TERMINALS OF EGU 2... Di-639 PROBLEM SYMPTOMS TABLE CIRCUIT INSPECTION... coceees DBASO'MGNOSTICS — ENGINE ENGINE y HOW TO PROCEED WITH TROUBLESHOOTING = ‘Troubleshoot in accordance with the procedure on the following page. ‘Tehica Brought to Workshop Titles inside ZZ are titles of pages in this manual with the page number indicated in the bottom portion, See the indicated pages for detailed explanations. 2 J Connect the OBD II scan tool or TOYOTA hand-held tester to DLGS P. DI-3 if the display indicates a communication fault in the tool, inspect DLC3 P. DI-S ‘Check DTC and Freezed Frame Data (Preched 7 Record or Pr DTC and Freezed Frame Dala P. DI-3 ]pre DIAGNOSTICS — ENGINE CUSTOMER PROBLEM ANALYSIS CHECK ENGINE CONTROL SYSTEM Chock Shoot] jupecore ‘Customer's Name ont and Model avers Name Frama No aa eae conse Na. Odometer Rosdng lee o does | 1 Engine does not crank QNc tnitlal combustion No compiete combustion Tpiteu to | Q Engine cranks slowly Ser" | oomer z Tinconect iret idle Cidingrpmisabnarnal OWgh( pm) low( 79) I SPeoriaing to Roughiding — (Oren Tipo, | Oveaision — Cleecktie Wwe oxplonlon(aHer-tre) Curing j Seveanomy | Crnocting Ob, i ‘soon ater suing Clater accelerator pede! depressed Dengine Stall | [After sccolerator pedal refeased 3 During A/C operation saiting omNtoD Comer Dothars Betas Problem Secured constant ClSomerinea( mes par Dlonce only Problem Frequency oo ‘wosther Drie Dciouty — Reiny Snowy Ch vertounromer, Outdoor " 8 [Fropouce [Oe vm Dost Bcetsappree “rod Bf ew mae Sees a om Brough rosa Other {E [EnsieTonpertwe| cold GWamingup Cater warming up _[ Anytempersture other staring Glavatetter staring min) ——_-Ollaing racing Engine Operation | [Driving __O.Constant speed Acceleration — DD eceteration TAC ewitch ONOFF Other Condition of ML. on C1Sometinea light does not ight up Normal ode {Di Mattunction codes (code > trrechecn) [iFreered frame data ( ) oretenpeaion ‘Biarmat Diaitunction cosets) ode ) ‘check Mode rrnesed rare det )bs DIAGNOSTICS —_ ENGINE PRE-CHECK 1. DIAGNOSIS SYSTEM (@) Description + When troubleshooting OBD Il vehicles, the only cit- ference from the usual troubleshooting procedure is that you connect to the vehicle the OBD Il scan tool complying with SAE J1978 or TOYOTA hand- held tester, and read off various data output from the vehicle's ECM, + OBD Il regulations require that the vehicle's on~ board computer lights up the Malfunction Indicator, Lamp (MIL) on the instrument panel when the com- [fey puter detects a malfunction in the emission control system/components or in the power train control components which affect vehicio emissions, or a ‘malfunction in the computer. In addition to the MIL lighting up when a malfunction is detected, the ap- plicable Diagnostic Trouble Code (DTC) prescribed by SAE J2012 are recorded in the ECM memory (See page DI-14), tf the malfunction does not reoccur in 3 consecutive, the MIL goes off automatically but the DTCs remain recorded in the ECM memory. + Tocheck the DTCs, connect the OBD Il scan too! or ‘TOYOTA hand-held tester to Data Link Connector 3 (DLC3) on the vehicle, The OBD HI scan too! or TOYOTA hand-held tester also enables you to erase the DTCs and check treezed frame data and various forms of engine data (For operating instruc- ions, see the OBD Ii scan tool's instruction book.). DTCs include SAE controlled codes and manutac- turer controled codes. SAE controlled codes must bbe sel as prescribed by the SAE, while manufactur er controlled codes can be set freely by the manufacturer within the prescribed limits (See DTC chart on page DI-14).DM DIAGNOSTICS ENGINE + The diagnosis system operates in normal mode during normal vehicle use. Italso has a check mode for technicians to simutate malfunction symptoms and troubleshoot. Most DTCs use 2 trip detection logic* to prevent erroneous detection, and ensure thorough maffunction detection. By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up tor a mal- function that is only detected once or momentarily (TOYOTA hand-held tester only) (See page Dia). + *2 trip detection logi When a malfunction is first detected, the malfunc- tion is temporarily stored in the ECM memory {1st tp). If the same malfunction is detected again during the second Charge or replace battery. YES 2 }Is engine cranked? wo) Proceed to page and continue to troubleshoot. YES 3. | Does engine start? covenDh DIAGNOSTICS —_ ENGINE 4 [Check air filter. PREPARATION Remove the air filter. CHECK: Visual check that the air filter is not dirty or excessive oily. HINT: Itnecessary, clean the filter with compressed air. First blow trom inside thoroughly, then blow from outside of the filter. Repair or replace. ie 5 | Check idle speed. PREPARATION: Warm up the engine to normal operating temperature, (b) Switch off all accessories. (©) Switeh off air conditioning. (2) Shift transmission into “N" position. {@) Connect the OBD il scan tool or TOYOTA hand-held tester to DLC3 on the vehicle. CHECK: Use CURRENT DATA to check the idle specd. Ok: Idle speed: 1ZZ-FE: 650-750 rpm NG \\| Proceed to problem symptoms table on page | >DL DIAGNOSTICS. — ENGINE 6 | Check ignition timing. PREPARATION: @ (b) ©) @) (e) ‘Warm up the engine to normal operating temperature, Shift transmission into "N’ position. Keep the engine speed at idle. Using SST, connect terminals 13 (TC) and 4 (CG) of the oLC3. SST 09643 - 18020 Connect the timing light. (CHECK: ‘Check ignition timing. OK: Ignition timing: 1ZZ-FE: 10 ~ 18° BTDC at idle 2Z2-GE: 8- 12" BTDC at idle NG | Proceed to page and continue to troubleshoot. Proceed to problem symptoms tabla on 7 | Check fuel pressure, PREPARATION: fa) (b) © @ ) ‘Be sure that enough fuel is in the tank. Connect the TOYOTA hand-held tester to the DLC3. ‘Turn the ignition switch ON and push TOYOTA hand-held tester main switch ON. Use ACTIVE TEST mode to operate the fuel pump. Please refer to the TOYOTA hand-held tester operator's manual for further details. (Ifyou have na TOYOTA hand-held tester, connect the positive (+) and negative (-) leads from the battery to the {uel pump connector (See page SF-6). CHECK: Gheck for fuel pressure in the fuel inlet hose when it is pinchedDet INE : ) Proceed to page SF-6 and continue to trouble- shoot. PREPARATION: (@) Disconnect the hight-tension cord from the spark plug. (b) Remove the spark plug. (6) Install the spark plug the high-tension cord. (A) Disconnect the injector connector. (©) _ Ground the spark plug. CHEC! ‘Check if spark occurs while engine is being cranked. NOTICE: To prevent excess fuel being injected from the Injectors during this test, don’t crank the engine for more than 5 10 seconds at a time. Proceed to page IG~1 and continue to trouble- ) Proceed to problem sy table on. 2 ymptoms | pageDL2 r NOTICE: DiGNOSMIGS ENGINE ENGINE OPERATING CONDITION ‘The values given below for "Normal Condition” are representative values, 90 a vehicle may still be normal even if Its value varies from those listed here. So do not decide whether @ part is faulty or not solely according to the "Normal Condition" here. (a) _ CARB mandated signals. ‘Normal Congton”| oman soe Toman cabaanbent usenet metus: [ipsam cose ra ay ma cacon ee mane pusoron ne [208-20 tr retone Iu ‘Racing without load (2,500jmm): ° VZZ-FEN12.3~ 179% m were. 7a eae tents ene ee a SE i ie ENGINE SPD Engine Speed AZZ-FE: 650-750 '222-QE (MT): 750-850 rpm 272-GE (AT): 700 ~ 800 rpm 1GN ADVANGE INTAKE AF Vericle Speed Vehicle Stopped: 0 knvh (0 ph) arin Advance: anon Timing of Cytnger No.1 ‘ing: TOC 10 ~ 18° otake Air Yomp. Sensor Valve Equivalent to Ambient Tein ozs B1,82 ‘a TEE FE 4-20 ome, paEe 5 Senha. " Few 1 Fon ee wear ow at TH Mas AP a es sauna ete 64-7 ¢nioe entree ap Ga ota Potion Soar te Fly Coan 816% Wrortieros Ceevaresanapoente: ee Fay Cs 8— 164 ovvom 6-0, Or Naps Cpl a ased upon Seo - 025 61.51 laos Ovo ithe: 01-08 eid Onyun Soa Fa Win Ba, oorre1.s1 cor exon (Sere as SHORT FT #1) Voltage Output of Heated Oxygen Sensor Bank 1. Sensor 2 | Driving a $0 kav (34 mph): 0.10.9 ¥ *rifno conditions are specifically stated for “idling”, It means the shift le is OFF ang all accessory switches are OFF. (®) TOYOTA Enhanced Signals. ver is at N or P position, the A/G switch vets tis ety Tae aaa ane ata ian te TERE no Tegan rge wit 1DHi3 Dignosnies —_ ENGINE ‘ing: uecTon Fualinjcton tie ores No.t P2EFE19 ~23 ms Inake i Cont Valve Duty Rao AC DUTY AATIO 12-FE:25~35% Sreina rato roy soeciaype AG ano | SEEFE25 35% STARTER SIG anor Sena osnting: ON cre sw [Cesed Trae Poon Signal iti uly Gosod: ON NOSIS NC Switch Signal [GON ON PNPSIG Parhieval Postion Swich Signet or W postion: ON ELEGTGL LOAD 6G etic! Load Signa Detogper Sw ON ON STOP UGHT GW. Step Lh Sth Signal Step swen ON ON SOUL PRESS Sw Power Stwaing OF Prossore Swich Set [Turmstearing whee: ON Fuel Cutie Flat won ona vale ty Foot Fuel est oparting: ON FOTAD Fuel Gut TAU: Fut tring voryightoad | Fuk ctoporaing OW CYLBI, GYLE2, CYLIG, CYL#A [Abnormal evolution variion fr each oylinder | o% Trad numberof ignition for every 1,000 sevets- = es o-2000 5m Tecra ito Se aan RennogurEH [wc ne sr MOH. yap runes wav [es en [sevens on waren [ wl ora eg ngs 4 vant VS a Vera Oe es tan: ne a rowrrar i tsa sig: 08-12 os pee San Ba or auras. xt tags i nen see lt | ne earn 0 00 me crest wih eet Ose Sve cana a conten. sr gee ee su |g tying 2180 mc sth rom reno Joan *: Ha conditions are specifically stated for “ldling’, it means the shift lever is atN or P position, the A/G switch is OFF and all accessory switches are OFF.ery Diagnostics —_ ENGINE DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may not be exactly the same as your reading dus to the type of instrument ‘or other factors. Ita malfunction code is displayed during the DTG check in check mode, cheok the circuit for that code listed inthe table below. Fordetails of each code, turn to the page referred to under the "See page "for the raspec- tive "DTC No.” in the DTG chart. SAE CONTROLLED: “rouble Area, MILT | Homony + Open or shorn mass alr flow mater circuit Mass ar ow moter ° ° +50M Maga ale owe metor ° ° + Opan or shorn intake alr tom. senior ccuit gk ale ternp. sensor (but int mas ai ow moter) ° ° com jo Open er shod in ongine coolant temp. sensor cuit ~Engino coolant temp. sensor ° ° EON Cong system ° ° Engine coolanttemp. sensor por Open or short in throtte pasion sensor drut ors) + Throte postion sensor ° ° ECM + Throtle postion sensor ° ° EOM Open a horn ated oxygen sensor (bank #seneor 1) ret -Hoaled cxygen sansa bark 1 sensor 1) + Aicindction system Fuel measure ° ° siusctor Gas eakage on exhaust sytem sou Open or shor in heated ongen sensor crew Heated Onygon Sensor Greuit Gora, |atecton ak Se: oe Joo (Exco Casty Opa oan nbd oo on" we Haste oxyen sense 0100 |omuen senor cr sew Ro. |*Arinuctin stom ° ° (0689) [pore (Oan tSunaeny | ECR eMC Siyecor seca roves crea | Senet deel en 5 , (085) | Matuncion ank 1 Sensor) | *Homod oxyaen sensor healDis DIAGNOSTICS — ENGINE Oxygen Sensor Great Matune- T+Opan or hom in healed oxygen sensor cru on (Bank + Sensor 2} Heated oxygen soncor oxygen Sensor Heater Gicut Maifuncion (ank 1 Senor 2} forse Pow (or-86) Same as DTC No. POTS iat mccaee teehee coer yc remmranrri |-ratpen o Jo Saag nat ton “Ceres nba se Cs oo mang etre pomeretrs tae Sent se ve eee mr leemeenneutriny |Sanee o | o Saget seen -Spornenace coger ore Cat sow oan mean myt bk ee pte got —- Cece noes cen Somers conte [en rape evmaw are owwass [core o fo Sree pene ser Sorecomenen tons nde tena | eect Swann Cylinder 4 Mistire Detected Valeo timing on ‘+ Open or short in knock sensor 1 circuit Pecks one | fare o | 0 +coM Open or short in evarksnalt postion sensor cleat | RandomAtutiple Cylinder Mstro Datocted + Crankshatt positon sensoe Signal plate (Ting bet guido) ° ° + Cearkshatt ting putoy com *Open or short in eamshal position sensor creat Poss | camsnat Postion Sensor. | «Camenalt pestion sansor ° ° (04-76) | cut Matuneion *Cambahat tering puloy { ECM Gas leakage on exhaust system 0420 | Catalet System Extioncy 89- | -Cpen cr shorn healed omygen sentorccut ° ° (01-78) |iow Threshold (Bank 1} Heated anygen sonsor Three-way catalytic convertor 0335 | Crankshaft Postion Sensor” (0474) | Grout Maturationone DIAGNOSTICS —- ENGINE | Evagerative Emlasion Controt | Syotem Mattenction ore |< Hose or tubo cracked, hoe, damaged cr loose sea! = Fuel ark cap incorectly installed + Fuol tank cap cracked or damages «Vacuum hose cracked, hole, Blocked, damagad or dscor- nected Fuel wank cracked, nole oF dameged + Charcoal canister cracked, hols or damaged Open oF shor in vapor proseure sensor cuit + vapor pressure senor + Fuol ark ove fil check vate cracked or damaged Eom Vacuum hoes cracked, hole, blocked damaged or ison- nected Open or short in vapor pressure sensor cout vapor prosur sensor ‘Open or short in VSV drut for EVAP V8 or VAP ‘Open or short in VSV circuit for vapor pressure sensor Poss | Eveperano Emission Contra | *¥SV or vaperprosora cancer Fae eee comtatseare | -Chacalcanierctked, holeo dansoad Fuel ak overt check vate cracked or msged sia Po4so @H4104) Open or shor in vapor passura senor circuit = Vapor proesure anton Poss secM (oH109 Comtinaon meter 600 * Open or shor in vehi spond sensor chit (0108) *Wobiie speed sonsor *EoM Open orahortin AC valve creat poses eIAG ae stuck or sad (om, | tte cont yeam Manco | -Oponor snot NC ante cet + Alnducon oyster seca “To +++ MIL lights upDM7 ——PIAGHOSTICS ENGINE MANUFACTURER CONTROLLED: aro cee | tatoo Tu Ave vas | say sera) | aan vom Sperthtia #1 aT kat an ann ct 62%, |ietercicn mancton no | weno coe o fo ston ether vou anki mes “Spm etnOF2an10ciutton te dnc G5 | te cst uaintin tos | rime o | Nozio col wh ote ‘ok inna - open enon tF2 ane kt tem ion ct Ee |rgmerckat uaknson ea | tna o fo Keston cir veow “tango mais “prot OF and GT cet en Nn E38 digit ctuttaneon os | "tigers So eo Jo -Kouitonca wit, rou : inca poner ak rans [Owtanet Ponte ir | ot an ononnaena 3%, festmancin Bungee [Sst o fo runniog) ECM rane” |i SoaiSerha ton | Mecha Gurang wooing bk i, |SemerCessmamote” | sors © ans Pon ancy_|-eou sakes rina [wreymastnconten | 008 (Or-12a} fay }+WVT controller assembly ° ° sec view [sopupn cn ooaan| Shtn pig ach ipaice asm, |e “Sevupnomen o | o sou rai “Opn bop one oe (oeagy [ECMEATT Matron Ect ° 2 aed eoyeouuainces | -ncecu o | o -Sanmieaentue Fray f-Oom oso COV cra ovoreanncionter | Cevipe we o | o cou Te |Ooen eaten OOV ce coveremaetontor | Crewe co | o rec -Oprorchorm Ova Pres? |ocvopenMalunetion tor | "OPA! ras |oove ceoverw o |Dee _-DIAGNOSTIGS ENGINE “Open of short in OCV eouit Pras? | OC Clove Matnetion or |"OPanor shri conus) |wvr-ty +eoM «Short in pavkineutral postion ewich cat y7eu | Parnteutras Poston Switch oe at + Parkdnoutral position switch function EON, ++ MIL lights up : 2ZZ-GE only AIT onlyDIAGNOSTICS — ENGINE PARTS LOCATION SV for Intake Air Control VSV for CCV\ PNP Switch Mass Air Flow Meter VSV for EVAP- VSV for Vapor Pressure SensorTERMINALS OF ECM [ayer] _feley| Replace mass air ilow mater.One DTC P0110 | Intake Air Temp. Circuit Malfunction CIRCUIT DESCRIPTION ‘The intake air temp. sensor is built into the mass air flow meter and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the intake air temperature, the lower the intake air ‘temperature, the greater the thermistor resistance value, and the higher the intake air temperature, the lower the thermistor resistance value (See fig.1). The air intake temperature sensor is connected to the ECM (See below). The 5V power source voltage in the ECM is ap- plied to the intake air temp. sensor from the terminal THA via aresistor R. ‘Thats, the resistor A and the intake air temp. sensor are con- nected 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 vol- ume to improve driveability during cold engine operation. If the ECM detects the DTC "P0110", it operates the fall safe function in which the intake alr temperature is assumed to bo 20°C (68°F). Open or chor i intake oir orp. enor cut ‘Intake ar ter. sensor (but nto mas lw mote) +50M P0110 | Open or shonin make ar tmp. sensor ctcit HINT: After confirming DTC P0110, use the OBD I scan tool or TOYOTA hand-held tester to confirm the intake ‘air tamperature from CURRENT DATA. memenagees ee 40°C 40°F Open _ circuit 1406 284") or more I ‘Short. ceaDh29 __DIAGNOSTICS_— ENGINE WIRING DIAGRAM Intake Air Temp. Sensor (Built into mass air flow meter) INSPECTION PROCEDURE HINT: + DTC P100 (Mass Air Flow Meter Circuit Matfunction), P0101 (Mass Air Flow meter Circult Range/Per- formance Ploblem), P0120 (Intake Air Temp. Circuit Malfunction), P0115 (Engine Coolant Temp. Cir- uit Matfunction) and P0120 (Throttie/Pedal Position Sensor/Switch "A" Circuit Malfunction) are output ‘simultaneously, E2 (sensor ground) may be open. + Read freeze frame data using TOYOTA hand-held tester or OBD Il 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 warmad up or not, the alfuel ratio tean or rich, etc. at the time of the malfunction.DIAGNOSTICS — ENGINE 1 | Connect OBD II scan tool or TOYOTA hand-held tester, and read value of Intake air temperature. PREPARATION: {@) Connect the OBD II scan tool or TOYOTA hand—hel tester to DLC3. {b) Tum the ignition switch ON and push the OBD II scan tool or TOYOTA hand-held tester main switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand-held tester. OK: =" Same as actual alr intake temperature. HINT: = Ifthere is open circuit, OBD II scan tool or TOYOTA hand-held tester indicates — 40°C (~ 40°F). + Hfthere is short circuit, OBD Il scan ool or TOYOTA handheld tester indicates 140°C (284°F) or more. ..Go to step 2. Eee ‘Check for intermittent problems. Bee page DI-2). 2 | Check for open in harness or ECM. @™ Intake Air Tomp. PREPARATION: (Disconnect the intake temp. sensor connector. (b) Connect sensor wire harness terminals together. (c) Tum the ignition switch ON. CHECK: Read temp, value on the OBD Il scan tool or TOYOTA hand-held tester. OK: Temp. value: 140°C (284°F) or more Gontirm good connection at sen: roplace IntakeDisi DIAGNOSTICS —_ ENGINE. 5 3 [snesttoronn in harness or ECM. PREPARATION: {@) Remove the ECM cover. (b) Connect between terminals THA and E2 of the ECM con- nector. HINT, In take air temp. sensor connector is disconnected. Betore checking, do a visual and contact pressure check for the ECM connector (See page IN-30). {c)_ Turn the ignition switch ON. CHECK: Road temperature value on the OBD Il scan tool or TOYOTA hand-held tester. Ok: ‘Temperature value: 140°C (284°F) or more 0K \\| Open in hamess between terminals E2 or THA, repalr or replace harness. Gontirm good connection at ECI replace ECM (See page Check for short in harness and ECM. PREPARATION: {@) Disconnect the mass airflow meter connector. (6) Tum the ignition switch ON. CHECK: Read temperature value on the OBD II scan tool or TOYOTA hand-held tester. Ok: ‘Temperature value: ~40°C (40°F) ‘OK | Replace mass air flow meter.p32 5 | Check for short in hamess or ECM. \ PREPARATION: (@) Remove the ECM cover. (©) Disconnect the E4 connector of the ECM. HINT: Intake air temp. sensor connector is disconnected. (©) _ Turn the ignition switch ON. . CHECK: Read temperature value on the OBD tI scan tool or TOYOTA hand-held tester. Ok: "~ ‘Femperature value: ~40°C (40°F) o*) Repair or replace harness or connector.DI-s3 nono __erging DTC | Pots Engine Coolant Temp. Circuit Malfunction CIRCUIT DESCRIPTION AA thermistor built into the engine coolant temp. sensor changes the resistance value according to the engine coolant temp, The structure of the sensor and connection to the ECM is the same as in the intake air! ‘temp. circuit maltunc- tion shown on page D+-28. If the ECM dotects the DTC P0118, it operates fail safe function in which the engine coolant temporature is assumed to be 80°C (176°F). prone. | Detection term Troubie Ares J Oper or amon engin colt amp. soso” cet ]Opan shat n engine coat amp. sensor ct Engin coat erp sarsr secu HINT: After confirming DTG P0115, use the OBD II scan tool or TOYOTA hand-held tester to confirm the engine coolant temp. from "CURRENT DATA". “erp. Sipayed Matton 10°C (40°F) Open cout 140° 254"R oc mee Show drei WIRING DIAGRAM Engine Coolant Temp. ECM ‘Sensor‘Db34 DiagNosTICS — ENGINE INSPECTION PROCEDURE HINT: + IEDTC P0100 (Mass Air Flow Meter Circuit Malfunction), P0101 (Mass Air Flow Meter Circuit Range/ Performance Problem), P0110 (intake Air Temp. Circuit Malfunction), P0115 (Engine Coolant Temp. Circuit Malfunction), P0120 (Throttie/Pedal Position Sensor/Switch "A" Circuit Malfunction) are output ‘simultaneously, E2 (sensor ground) may be open. «Read ireeze frame data using TOYOTA hand-held tester or OBD il scan tool. Because freeze frame fecords the engine conditions when the malfunction is detected, when troubleshooting itis usetul for determining whethor 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. 4 | Connect OBD Il scan tool or TOYOTA hand-held tester, and read value of engine coolant temperature. PREPARATION: {@) Connect the OBD 1! scan tool or TOYOTA hand-held tester to the DLCS. (b) Tum the ignition switch ON and push the OBD I! scan tool or TOYOTA hand-held tester main switch ON. GHECK: Read temperature value on the OBD II scan tool or TOYOTA hand-held tester. OK: ~~" Same as actual engine coolant temperature HINT: + IWthere is open circuit, OBD I! scan too! or TOYOTA hand-held tester indicates ~40°C (40°F). * — ifthereis open circuit, OBD Il scan tool or TOYOTA hand —held tester indicates 140°C {284°F) or more. —40"C (40°F) ... Go to step 2. 140°C! ‘baer Sethore Soto step 4. ‘Check for intermittent problem:Drs —paanosrics —_ENGiNe ° Check for open In harness or ECM. PREPARATION: (@) Disconnect the engine coolant temp. sensor connector. (®) Connect the sensor wire harness terminals together. (©) Turn the ignition switch ON. CHECK: Road lemperature vaiue on the OBD II scan tool or TOYOTA hand-held tester. OK ‘Temperature value: 140°C (284°F) or more Contirm good connection at sensor. It OK, replace engine coolant temp. Engine Coolant ‘Temp. Sensor PREPARATION: {a} Remove the ECM cover, (b} Connect between terminals THW and E2 of the ECM con- nector. HINT: Engine coolant temp. sensor connector is disconnected, Be- fore checking, do a visual and contact pressure check for the ECM connector (See page IN~30). (©) Tum the ignition switch ON. CHECK: Read temperature value on the OBD Il scan tool or TOYOTA hand-held tester. Ok: “~~ Temperature value: 140°C (284°F) of more SY Open in harness between terminals 2 or THW, repair or replace harness.pias oO Engine Coolant ‘Temp. Sensor 5 | Check for short in harness or ECM. 4 | Check for short in harness and ECM. PREPARATION: (@ _ Disconnect the engine coolant temp. sensor connector. (6) Tum the ignition switch ON, CHECK: Read temperature value on the OBD Il scan tool or TOYOTA ont tester. ~~ Temperature value: — 40°C (- 40°F) S Roplace engine coolant temp. sensor. PREPARATION: (@)_ Remove the ECM cover. (b) _ Disconnect the E4 connector of the ECM. HINT: Engine coolant temp. sensor connector is disconnected. (©) Tum the ignition switch ON. CHECK: Read temperature value on the OBD Il scan tool or TOYOTA han-neld tester, ~~ Temperature value: ~40°C (40°F) IK >| Repair or replace harness or connector. ‘Check and replace ECM (See page IN-30).+ 01-37 puagNosmes — ENGINE oTc P0116 | Engine Coolant Temp. Circuit Range/ Performance Problem CIRCUIT DESCRIPTION Refer to DTC P0115 (Engine Coolant Temp. Circuit Malfunction) on page DI-33. DTC Detecting Conan temp. sensor aun fs 20°C (68°F) or ls (2p detecion ogc) When the engine start, the water torp. is betwoon -7 20°F) and 10°C (60°F) pons emp. sensor value 20°C (65°F orion 2p detection og Whi the engine stats, tho war tomp. fe -7°C (20°F) or les. And, 20 in. oF moro afar e engine stare, ho englne And, S min. or more afer he engine stats, te engine coctant Troube Area +Fnging coolant temp, conor Coating system INSPECTION PROCEDURE HINT: 1 DTG PO115 (Engine Coolant Temp. Circuit Malfunction) and P0116 (Engine Coolant Tamp. Circuit Range/Pertormance Problem) are output ‘simultaneously, engine coolant temp. sensor circuit may be ‘open. Perform troubleshooting of DTC PO115 first. + Read freeze frame data using TOYOTA hand-held tester or OBD I! 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 oF rich, eto. at the time of the malfunction. _ 1 | Are there any other codes (besides DTC P0116) being output? YES )| Go to relevant DTC chart, L 2 | Check thermostat (See page CO-8). | NG )| Replace thermostat. SI__DIAGNOSTICS — ENGINE DTC P0120 CIRCUIT DESCRIPTION Throttle Position Sensor/Switch ”A” Circuit Maltunction ‘The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttte valve is fully closed, a voltage of approximately 0.3 -0.8 Vis applied to terminal VTA of the ECM. The voltage appiiad to the term nals VTA of the ECM increases in proportion to the opening angle of the throttle vaive and becomes approximately 3.2—4.9 V when the thrattle vaive is fully opened. The ECM judges the vehicle driving conditions from this signal input from terminal VTA, and uses it as one of the conditions for deciding the air— fuel ratio correction, power increase correction and fuel-cut control ete. ‘DIC Datecing Conction Troubye Area Constr (8) (0) eontinves wath more han 6 sea: ‘Open of shot in thotle poston sensor cult ‘Thott positon sensor som HINT: After confirming DTG P0120, use the OBD II scan tool or TOYOTA hand-held tester to confirm the throttle valve opening percentage. “Tote valve oping postion oprnnsec an peroanings ‘Treube are “Thro vale ily op07 1 ‘VG ine open om YEA oa open of short l ‘Approx. 100% ‘Approx, 100% Ezting open,1-39 DwGNOSTICS ENGINE WIRING DIAGRAM INSPECTION PROCEDURE HINT: + ITC P0100 (Mass Air Flow Meter Ciecuit Malfunction), P0106 (Mass Air Flow Meter Circuit Range/ Performance Problem), P0110 (Intake Air Temp. Circuit Maltunction), P0115 (Engine Coolant Temp. Circuit Maltunction), P0120 (Throttle/Pedal Position Sensor/Switch "A" Circuit Malfunction) ate output simultaneously, E2 (sensor ground) may be open. + Read freeze frame data using TOYOTA hand-held lester or OBD Il scan tool. Because freeze frame Fecords the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicte was running or stopped, the engine warmed up or not, the air-fuel ratio lean or rich, etc. at the time of the malfunction.Deo © © we) 4 | Connect the OBD Il scan tool or TOYOTA hand-held tester, read the throttle valve opening percentage. PREPARATION: {@ Connect the OBD II scan tool or TOYOTA hand-held tes- ter to OLS. (0) Tum the ignition switch ON and push the OBD Il scan toot ‘or TOYOTA hand-held tester main switch ON. CHECK: Read the throttle valve opening percentage. ox: atiahe ans ton Tove ree oa (=n repre 70% a | repre 10% ‘Check for intermittent problems (Soe page Di-3). @™ ON aw) Fran round between terminal VC of throttle position sensor connector and PREPARATION: {a)__ Disconnect the throttle position sensor connector. {b} Turn the ignition switch ON. CHECK: Measure voltage between terminal VC of the throttle position ‘connector and body ground.Dhat DIAGNOSTICS — ENGINE ) : Check throttle position sensor (See page SF-33). [r= Replace throttle position sensor, | 4 [omer Voltage between terminals VTA and E2 of ECM connector. PARATION: @ Remove the ECM cover. (b) _ Tum the ignition switch ON. CHECK: Measure voltage between terminals VTA and E2 of the ECM connector. ol Trot wave Voteoe Fully closed 03-104 Fay open 32249v ) Check for open and short in harness and con- Oo nector between ECM and throttle position sen- sor (VTA or E2 tine) (See page )). Check and replace ECM (See page IN-30).ona 5 | Check voltage between terminals VC and £2 of ECM connector. PREPARATION: (@) Remove the ECM cover. Prec Turn ignition switch ON. mane voltage between terminals VC and E2 of the ECM connector. ok: Voltage: 4.5~5.5V [ Check and repiace ECM (See page IN-30). (Check for cen in harneeg and connector be- tween ECM and ‘sensor (VC line) {See page IN-80)-Dias DIAGNOSTICS — ENGINE >) DTc | P0121 | Throttte/Pedal Position Sensor/Switch A” Circuit Range/Performance Problem CIRCUIT DESCRIPTION Refer to OTC P0120 (Throttle/Pedal Position Sensor/Switch "A” Circuit Malfunction) on page DI~38. Trouble Area + Thole postion sentor seCM INSPECTION PROCEDURE HINT: Read froeze frame data using TOYOTA hand-held tester or OBD Il scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whother the vehicle was running or stopped, the engine warmed up or not, the air-fuol ratio lean or rich, ate. at the time of the malfunction. 1 | Are there any other codes (besides DTC P0121) being output? ) [v= Go toreivant OTC cher. Ce) Replace throttle position sensor.bas uugNosTICS - ENGINE bTc P0125 | Insufficient Temp. for Closed Loop Fuel Control! CIRCUIT DESCRIPTION ‘To obtain a high purification rate for the CO, HC. and NOx components of the exhaust gas, a three-way catalytic converter is used, but for the most efficiant use of the three-way catalytic converter, the air-fuel ratio must be precisely controlled so that itis 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-tue! ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN candition (small electromotive force: < 0.45 V). ‘When the air-fuel ratio is RICHER than the stoichiometric air-fuel ratio the oxygen concentration in the ex- ‘aust gas in reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive fores: > 0.45V). ‘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 oul- ‘put 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. ‘Atmosphere db Ideal Ait-Fuel Micture: Flange Pratrum Eectode Solid Electrot eRe remy 8 Platinum Electrode 3. Heater 3 Coating (Ceramic) Ficher— Air Fuel Ratio - Leaner Tet Aa “Fonayaa Anat saga a warmed up yin ars ak sear | “Arnon eon Mowacornaiacaerion(s oss owner von [ACS pondions (a), (6, and (c) continue frat east 1.5 rin, cea eee. eenustoysem fe) Engine spond: 1200 or mere + Open or short ineated oxygen sensor foank 1 sensor 1) Cb} Venice spoad: 40 100 km (25~62:mph) Open ce) Teote valve doesnot ity closed ‘+ Heated oxygen sonsor (bank 1 sensor 1) comHINT: ‘After confirming DTG P0125, use the OBD IIscan tool or TOYOTA hand-held tester to confirm voltage output ‘of oxygen sensor {bank 1 sensor 1) from "CURRENT DATA’. Nvottage output of oxygen sensor (bank 1 sensor 1) isless than 0.1 V, oxygen sensor (bank 1 sensor 1) circuit may be open or short. WIRING DIAGRAM _— Engine Room J/B a1 f 7 iB ES) MREL Idle Air Control Valvepee DIAGNOSTICS_— ENGINE INSPECTION PROCEDURE HINT: «Ifthe vehicle run out of fuel, the air—fuel ratio is LEAN and DTC P0125 will be recorded . ‘The MIL then comes on. + Read freeze frame data using TOYOTA hand-held tester or OBD Ii scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmed up or not, the air-fuel ratio fean of rich, ete at the time of the malfunction. 1. | Are there any other codes (besides DTC P0125) being output ? YES )| Go to relevant DTC chart. LJ 2 [Connect the OBD Il scan tool or TOYOTA hand-held tester and read value for voltage output of oxygen sensor (bank 1 sensor 1). PREPARATION: {@ Connect the OBD I! scan tool or TOYOTA hand-held tester to the DLC3. (b) Warm up engine to normal operating temp {above 75°C). CHECK: Read voltage output of the oxygen sensor (bank 1 sensor 1) when engine is suddenly raced. HINT: Perform quick racing to 4,000 rpm 3 times using accelerator pedal. OK: ~~ woth oxygen sensor (bank 1 sensor 1) output a RICH signal (0.45 V or more) at least once, Da e [3 Check for ‘and short in harness and connector between ECM and oxygen Sensor (bank ‘sensor 1) (See page IN-30). | Repair or replace harness or connector. [oJDar DIAGNOSTICS — ENGINE. +) [+ Check whether mistire is occurred or not by monitoring DTC and data list. [> Perform troubleshooting for mitre (See page | 5 | Check air induction system (See page SF-1). | NG >| Repair or replace induction system. [ 6 [p= fuel pressure (See page SF-6). : Check and repair fue! pump, tue! pipe line and ) No | Grace ropa fun ve 7 Teves injector Injection (See page SF-22). = | =DHas DIAGNOSTICS — ENGINE _ 8 | Check gas leakade on exhaust system. | NG )/ Repair or replace. Replace oxygen sensor {bank 1 sensor 1). 9 | Perform confirmation driving pattern (See page DI-49). o 40 | Is there DTC P0125 being output again? - Check and replace ECM. | n [oi vet re out of nthe pst No )| Check for intermittent problems. DTC P0125 Is caused by running out of fuel.pyawosTics —ENGNE + DTc P0130 | Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control) on page DI-44, Open o shat in bested oxygen sensor chou + Heated anygen sensor Votage outpetof onfgen sensor remain at 04 V or move, or | +Alcinducton sys 0.55 V or les, during ding lterthe engine is warmed up (2 | +EGA system ep dorotion logic) Fuel pressure injector SECM HINT: ‘Sensor 1 refers to the sensor closer to the engine body. ‘The oxygen sensor's output voltage and the short-term fuel trim value can be read using the OBD It scan tool or TOYOTA hand—held tester. WIRING DIAGRAM Refer to DTC P0125 (Insufficient Coolant Temp. for Clased Loop Fue! Control) on page DI-44 for the WIR- ING DIAGRAM.Db8o CONFIRMATION DRIVING PATTERN (1) Connect the TOYOTA hand-held tester o the DLC3. (2) Switch the TOYOTA hand-held tester from normal mode to check mode (See page DI-3). (3) Start the engine and let the engine idle for 100 sec. or more. (4) Drive the vehicle at 40 krrvh (24 mph) or more for 20 sec. or more. (8) Let the engine idle for 20 sec. or more. (6) Let the engine idle for 30 sec. HINT: if a malfunction exists, the MIL will light up during step (6). NOTICE: If the conditions In this test are not strictly followed, detection of the malfunction will not be possibl Hf you do not have a TOYOTA hand-held tester, turn the Ignition switch OFF after performing steps (3) to (6), then pertorm steps (3) to (6) again. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand-held tester or OBD Il scan tool. Because freeze frame records the engine conditions when the maifunction 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 maifunction. 1 [are there any other codes (besides DTC P0130) being output? Go to relevant DTC chart. LeDist DIAGNOSTICS — ENGINE +) [ 2 “|e the output voltage of oxygen sensor during Idling. PREPARATION: ‘Warm up the oxygen sensor the engine at 2,500 pm for approx. 90 sec. CHECK: Use the OBD II scan tool or TOYOTA hand-held tester read the output voltage of the oxygen sensor during Bg a oxygen sensor output voltage: Alternates repeatedly between less than 0.4 V and more than 0.55 V (See the Following table). Perform confirmation driving pattern (See page DI-49), Check tor open and shor In harness and connector between ECM and oxygen ik t sensor’) (See page IN-20), NG_ | Repair or replace hamess or connector. [ | Check air induction system (See page SF-1). NG >| Repair or replace induction syster ) =_biaawosncs ~ enone Check fuel pressure (See page SF-6). ["=) Cheek and repair fuel pump, fuel pipe line and. | filter (See page SF-1). Check Injector injection (See page SF-22). Replace Injector. Replace oxygen sensor (bank 1 sensor 1). | lw) 7 | Pertorm contirmation driving pattern (See page DI—49). Are there DTC P0130 being output again? ‘Check for intermittent problems (Gee page D3). Check and replace ECM. |DIAGNOSTICS — ENGINE. pTc P0133 | Oxygen Sensor Circuit Slow Responce (Bank 1 Sensor 1) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Controf) on page DI-44, DICH. [DTC Detecang Gonetion I “Trouble Area “Spanair soa sooty to | tated cngeromen pag [Prentomantinn aiaraer tesa one |More asta yu nresaa up Eaton (teeming) “gear ou ‘HINT: ‘Sensor 1 refers to the sensor closer to the engine body. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand-held tester or OBD Il scantool. Because freeze frame records the engine conditions when the mattunetion 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, ete. at the time of the malfunction. 1 [are ‘there any other codes (besides DTC P0133) being output? | cSDIAGNOSTICS ENGINE _ Check the output voltage of oxygen sensor during idling. PREPARATION: ‘Warm up the oxygen sensor the engine at 2,500 rpm for approx. 80 sec. CHECK: Use the OBD II scan too! or TOYOTA hand-heid tester read the output voltage of the oxygen sensor during idling. OK: Oxygen sensor output voltage: Alternates repeatedly botweon less than 0.4 V and more than 0.55 V (See the Foliowing table). Pertorm confirmation driving pattorn {See page DI-49). 3 | Check for open and short in hamess and connector between ECM and oxygen ‘sensor (! 1 sensor 1) (See page II [= pronto acme | induction system (See page SF-1 Ropair or replace induction system.DIAQNOSTICS —_ ENGINE [otek fuel pressure (See page SF—6). oO » Check and repair fuel pump, fuel pipe line and filter (Soe page SF). "We! Pipe line a 6 | Check injector injection (See page SF-22). == Replace oxygen sensor (bank 1 sensor 1). 7 | Perform confirmation driving pattern (See page Di-49). Are there DTC P0133 being output again? heck for intermittent problems {See page DES).186 BunghosTICS — ENGINE pTc P0135 | Heated Oxygen Sensor Heater Circuit Malfunction (Bank1 Sensor1) DTc P0141 | Heated Oxygen Sensor Heated Circuit __| Malfunction (Banki Sensor2) CIRCUIT DESCRIPTION Refer to DTC P0125 (Insufficient Coolant Temp. for Closed Loop Fuel Control) on page Di-44. Trouble Area. Open or shor tn heater cet at heated cxygen sensor Hosted oxygen sensor nestor -EOM HINT: + Bank 1 refers to the bank that includes cylinder No.1. + Sensor 1 refers to the sensor closer to the engine body. + Sensor 2 refers to the sensor farther away from the engine body. ‘WIRING DIAGRAM Refer to DTC P0125 on page DI~44 for the WIRING DIAGRAM. INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand-held tester or OBD I! scan tool. Because freeze frame records. the engine conditions when the maltunction 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.DLS7 DIAGNOSTICS ENGINE fy | 1 ‘Tees: voltage between terminals HT1, HT2 of ECM connectors and body ground. PREPARATION: @) Remove the ECM cover. {0} Remove the 3 bots from ECM. (©) Tum the ignition switch ON. CHECK: Measure voltage between terminals HF1A, HT1B of ECM con- nectors and body ground. HINT: + Connect terminal HT1A to bank 1 sensor 1. + Connect terminal HT1B to bank 1 sensor 2. OK: ~ Voltage: 9-14 «| ‘Check and replace ECM (See page IN-30), | 2 [neck resistance of heated oxygen sensor heater (See page SF-70). NG >| Reptace heated oxygen sensor. Check and ir harness or connector between main relay (Marking: EFI), heated oxygen ‘sensor and ECM (See page IN-30).[ oTC P0136 Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) CIRCUIT DESCRIPTION Reter to DTC P0125 (\nsuflicient Coolant Temp. for Closed Loop Fue! Control} on page DI~44. DICK. (OTC Detecting Goneton Trouble Area P0136 Voltage output of he heated oaygon eontor remains at 0.40 V_ or more, oF 0.50 V orless when the vahll a criven at 40 kwh | «Open or short in heated oxygen sensor circuit (25 moh) or more afer the engine is warmed up + Heted oxygen sensar (2 tip detection oo). HINT. ‘Sensor 2 refers to the sensor farther away from the engine body. WIRING DIAGRAM Refer to DTC PO125 (Insufficient Cootant Temp. for Closed Loop Fuel Control) on page DI-44 for the WIR- ING DIAGRAM. CONFIRMATION DRIVING PATTERN (a) (b) © (¢) (e) {) HINT: ‘Connect the hand-held tester to the DLC3. ‘Switch the hand-held tester from the Normal Mode to the Check (Test) Mode (See page DI-3). ‘Start the engine and let the engine idle for 60 seconds or more. Drive the vehicle at 30 kavh (18 mph) of more for 40 seconds or more. Lettthe engine idle for 10 seconds or more. Preform stops (d) to (2) 9 times, {t matfunction exists, the CHK ENG (MIL) will be indicated on the mult! information display during step (f). NOTICE: ifthe conditions in this test are not strictly followed, detection of the malfunction will not be possible. Ht you do not have a hand-held tester, turn the ignition switch OFF after performing steps (c) to (1), then pertorm steps (c) to (f) again.DIAGNOSTICS —_ ENGINE INSPECTION PROCEDURE HINT: Read freeze frame data using TOYOTA hand-held tester or OBD iI scan tool. Because freeze frame records the engine conditions when the malfunction is detected, when troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine warmad up or not, the air-fuel ratia lean or rich, etc. at the time of the malfunction. + | Are there any other codes (besides DTC P0136) being output? YES }| Go to relevant DTC chart. 2 |Check for open and short in harness and connector between ECM and oxygen sensor (See page IN-20). | > Repair or replace harness or connector. 3 | Check output voltage of oxygen sensor. PREPARATION: (a) Connect the OBD II scan tool or TOYOTA hand-held tester to the DLC3. (©) _ Warm up the engine to normal operating temp. CHECK: Read vottage output of oxygen sensor when engine suddenly raced. HINT. Perform quick racing to 4,000 rpm 3 min. using accelerator pedal. Ok: ‘Oxygen sensor output voltage: Alternates from 0.40 V or less to 0.60 V or more. connected. > Check that each connector Is properlyDi6o DIAGNOSTICS — _ENGING | DTC | P0171 | system too Lean (Fuel Trim) [pre | poze | System too Rich (Fuel Trim) CIRCUIT DESCRIPTION Fue! trim refers to the feedback compensation value compared against the basic injection time. Fuel tim includes short-term fuel trim and long-term fuel tim. ‘Short-term fuel trim is the short-term fuel compensation used to maintain the air—tuel ratio at its ideal theoretical value. The signal from the oxygan sensor Indicates whether the air—tuel ratio is RICH or LEAN compared to the ideal theoretical value, triggering a reduction in fuel volume if the air-fuel ratio is rich, and an increase in {uet volume itt is lean. Long-term fuet trim is overall fuel compensation carried out long-term to compensate for continual deviation of the short-term fuel trim from the central value due to individual engine differences, wear over time and changes in the usage environment. lf both the short-term fual trim and long-term fuel trim are LEAN or RICH beyond a certain value, It is. detected as a malfunction and the MiL lights up. (OFC Detecting Condon “Trouble Area “Air inducilon aston iecer boksge ents siren ning Maw 0, nue mi consderany er onto ici sise | "Ot oa @ mp cetecton oni) ae aakage on exhaust system + Open or short in AF sensor bank 1 sensor thecut NE sensor (bank 1 sonsor 1} jetr lak Hockane Mass ar ow malar + Engine cola temp. sor Wien th ai-tul ao feedbacks stabi ator angino waning | stoion system up, te tl mi considerably eros onto LEAN cide. | «Fua prossura (2p detection tog) + Gas antago on exhaust ystem Open or shor in meted oxygon sensor (bank 1 senacr 1) ereut [+Hosied nyoen onaor (bank sensor ty © When the DTC 0171 is recorded, the actual ait-fuel ratio is on the LEAN side. When DTC P0172 is, recorded, the actual alt-fuel ratio is on the RICH side. + Ifthe vehicle runs out of fuel, the air-fuel ratio is LEAN and DTC P0171 is recorded. The MIL then comes on. ‘+ ifthe total of the short-term fuel trim value and long-term fuel trim value is within 4 98 %, the system is functioning normally. + The oxygen sensor output voltage and the short-term fuel trim value can be read using the OBD Il scan too} or TOYOTA hand-held tester.Diet omgnosnes — ENGINE +y 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 ior determining whether the vehicle was running or stopped, the engine warmed up or not, the air-fuel ratio lean or tich, etc. at the time of the malfunction. 1 [ote air Induction system (See page SF-1). = (J [2 ‘Check injector injection (See page SF-22). NG )| Replace injector. nd engine coolant temp. sensor Ws) Repair or replace. 4 | Check for spark and ignition (See page IG—1). NG | Repair or replace. [J5 | Check fuel pressure (See page SF-8). No Check and repair fuel sure regulator, fei pipe ineend titer, Pe [«] 6 | Check gas teakade on exhaust system. NG_)| Repair or replace. oK Check the output voltage of oxygen sensor during Idling PREPARATION: ‘Warm up the oxygen sensor the engine at 2,500 rpm for approx. 90 sec. CHECK: Use the OBD I! scan tool or TOYOTA hand-held tester read the output voltage of the oxygen sensor during idling. OK: ‘Oxygen sensor output voltage: Alternates repeatedly between less than 0.4 V and more than 0.55 V (See the following table). sou Goto step 9.DL63 DIAGNOSTICS —_ ENGINE ) [ 8 [Shes ‘eccren land short in hamess and connector between ECM and oxygen | sensor (See page IN-20). [= Repair or reptace harness or connector. Replace oxygen sensor. [» [Petre contmaton ring pater (S0 page I-40, | J | | Is there DTC P0171 or P0172 being output again? = eS | W [>t voce rane out th ne pa? [») ‘Check for Intermittent problems. '71 or P0172 is caused by running outDIAGNOSTICS _—_ ENGINE DTC P0300 | Random/Multiple Cylinder Misfire Detected [ DTC P0301 | Cylinder 1 Misfire Detected DTC P0302 | Cylinder 2 Misfire Detected DTc P0303 | Cylinder 3 Misfire Detected , pTc P0304 | Cylinder 4 Misfire Detected CIRCUIT DESCRIPTION Misfire: The ECM uses the crankshaft position sensor and camshatt position sensor to monitor changes in the crankshaft rotation for each cylinder. ‘The ECM counts the number of times the engine speed change rate indicates that misfire has occurred. And when the misfire rate equals or exceeds the count indicating that the engine condition has deteriorated, the MIL lights up. If the misfire rate is high enough and the driving conditions will cause catalyst overheating, the MIL blinks when misfiring ocours. TEN. TC Detecting Gondiion “Trouble eo “Open orahortn engine wre Connector eannection = Vacuurthose connection arition system 10300 | Misting of random oyindors is detacted during any parteuar | «injector 0301 | 200011000 revotsons =Fuelpesseue 20302 | Foranyparcuiar 200 revehsions forthe engine, misting is | «Marit abtolde pressure sonsor 0903 | detected which can cause catalyst overheating Engine coolanttomp. sensor osos | Ths causea tt to ina) Compression pressue Nelo dewrance Vane ting WL system (Locker arm) BOM HINT: When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no random misfire code is recorded, it indicates that the mistires were detected and recorded at different times.DGS DIAGNOSTICS —_ ENGINE CONFIRMATION DRIVING PATTERN @ ) © @) HINT: Connect the TOYOTA hand-held tester or OBD II scan tool. Record DTC and the freeze frame data. Use the TOYOTA hand-held tester to set to Check Mode (See page Di-3). Drive the vehicle several times with the engine speed, load and its surrounding range shown with EN- GINE SPD, CALG LOAD in the freeze trame data or MISFIRE RPM, MISFIRE LOAD in the data list Ifyou have no TOYOTA hand-held tester, turn the Ignition switch OFF after the symptom is simulated the first time. Then repeat the simulation process again. In order to memorize DTC of mistire, itis necessary to drive around MISFIRE RPM, MISFIRE LOAD in the data list for the following period of time. ‘Siminutes 90 soconds oc mor ‘Sines o¢ more 1 minute 30 seconds or more {minute of more {e) Check whether there is misfire or not by monitoring DTC and the freeze frame data. After that, record o ‘them. ‘Tum ignition switch OFF and wait at least 5 seconds.o1-67 DIAGNOSTICS ENGINE INSPECTION PROCEDURE HINT: CHECK: (@) Check the connection conditions of wire harness and connector. (b) lvis the case that DTC besides misfire is memorized simultaneously, first perform the troubleshooting for them. Read freeze frame data using TOYOTA hand-held tester or OBD Il scan tool, Because freeze frame data records the engine conditions when the malfunction is detected, when troubleshooting it is uselul {for determining whether the vehicle was running or stopped, the engine warmed up or not, the air-fuel ratio lean or rich, otc. at the time of the maifunction, When the vehicle is brought to the workshop and the misfire is not occurred, mistire can be confirmed by reproducing the condition or freeze frame data. Also, after finishing the tepair, confirm that there is no misfire. (See the confirmation driving pattern) When either of SHORT FT #1, LONG FT #1, SHORT FT #2 or LONG FT #2 in the freeze frame data {s besides the range of 20%, there is a possibilty that the air-fuel ratio is inclining either to "rich" {20% or less) or “lean” (+20% or more). ‘When COOLANT TEMP in the freeze frame data is less than 80°C (176°F), there is a possibilty or misfire only during warming up. {n the case that misfire cannot be reproduced, the reason may be because of the driving with lack or fuel, the use of improper fuel, a stain of ignition plug, and etc. Check wire harness, connector and vacuum hose in engine room. ‘Check the disconnection, piping and break of vacuum hose. Repair or replace, then contirm that there is no ["*> mistre (See the contirmatton driving pattern),