> 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.