Toyota - Camry - Workshop Manual - 1992 - 1992

AC–1 AIR CONDITIONING SYSTEM – AIR CONDITIONING SYSTEM AC–2 AIR CONDITIONING SYSTEM – GENERAL DESCRIPTION GENERAL DESCRIPTION NEW AIR CONDITIONING SYSTEM WITH R134a Refrigerant R12 (CFC12), previously used in automo– biles air conditioning systems is believed to contribute towards the depletion the earth’s ozone layer. The ozone layer help to protect us against the harmful ultraviolet rays of the sun. A newly developed refrigerant, R134 a (HFC 134 a), does not the destroy the ozone layer. PRECAUTIONS FOR SERVICING R134a AIR CONDITIONERS 1. USE OF NEW REFRIGERANT R134a The very different characteristics of refrigerants R134a and R12 have determined the design of their respective air conditioning systems. Under no circum– stances allow R12 to enter an R134a system, or vice versa, because serious damage could occur. 2. USE OF PROPER COMPRESSOR OIL Compressor oil used in conventional R12 air condi– tioning systems cannot be used in R 134a air condi– tioning systems. Always use genuine Toyota R1 34a air conditioning oil N D – OIL 8, made expressly for use with R 1 34a. If even a small amount of the wrong oil is changed, it will result in clouding of the refrigerant. A large amount will cause the compressor to seize up. AC–3 AIR CONDITIONING SYSTEM 3. – GENERAL DESCRIPTION USE OF PROPER O – RINGS AND SEALS 0–rings and seals used for conventional R12 air conditioning systams cannot be used for R134a air conditioning systems. Always use genuine Toyota R 134a system 0–rings and seals for R 1 34a air conditioning systems. If O–rings and/or seals for R1 2 air conditioning sys– tems are used by mistake in the connections of an R 134a air conditioning system, the O–ring and seals will foam and swell resulting in leakage of refrigerant. 4. TIGHTEN CONNECTING PARTS SECURELY Securely tighten the connecting parts to prevent leak– ing of refrigerant gas. Apply a few drops of compressor oil to 0–ring fittings for easy tightening and to prevent leaking of refrigerant gas. CAUTION: Apply only ND–OIL 8 compressor oil Tighten the nuts using 2 wrenches to avoid twist– ing the tube. Tighten the 0–ring fittings or the bolted type fittings to the specified torque. 5. 6. 7. INSERT PLUG IMMEDIATELY IN DISCONNECTED PARTS Insert a plug immediately in the disconnected parts to prevent the ingress of moisture and dust. DO NOT REMOVE PLUG FROM NEW PARTS UNTIL IMMEDIATELY BEFORE INSTALLATION DISCHARGE GAS IN NEW COMPRESSOR FROM CHARGING VALVE BEFORE INSTALLING IT If the gas in the new compressor is not discharged first, compressor oil will spray out with gas when the plug is removed. AC–4 AIR CONDITIONING SYSTEM – GENERAL DESCRIPTION SERVICE TOOLS FOR R134a AIR CONDITIONER When servicing R134a air conditioning systems always use the R134a dedicated manifold gauges, gas leak detector and vacuum pump adaptor. 1. USE MANIFOLD GAUGES FOR R134a AIR CONDITI– ONER Always use R134a dedicated manifold gauges to pre– vent R1 2 and RI 2 compressor oil contaminating the R 134a system. 2. USE R134a GAS LEAK DETECTOR Similarly, always use an R 134a dedicated leak detec– tor. The R1 2 leak detector is not sufficiently sensitive. 3. USE VACUUM PUMP ADAPTER By connecting a vacuum pump adapter, the vacuum pump can be used for both R 134a and R 12 air condi– tioning systems. The vacuum pump adaptor has an internal magnetic valve. When evacuation is completed and the vacuum pump switch is turned off, the magnetic valve opens allow– ing the introduction atmospheric air into the manifold gauges to prevent the back flow of oil from the vacuum pump into the gauge hose. CAUTION: Be sure to turn off the manifold gauge valve immediately after evacuating the system. Then you may switch off the vacuum pump. If this order is reversed, the line will be temporarily open to atmosphere. AC–5 AIR CONDITIONING SYSTEM – GENERAL DESCRIPTION HANDLING PRECAUTIONS FOR REFRIGERANT 1. 2. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME ALWAYS WEAR EYE PROTECTION 3. BE CAREFUL THAT LIQUID REFRIGERANT DOES NOT GET IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: (a) Wash the area with lots of cool water. CAUTION: Do not rub your eyes or skin. (b) Apply clean petroleum jelly to the skin. (c) GO immediately to a physician or hospital for profes– sional treatment. HANDLING PRECAUTIONS FOR REFRIGERANT CONTAINER 1. 2. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT CHARGING AND LEAK–CHECK METHODS Evacuate the refrigeration system according to the following procedures. 10 min. Start Evacuation Leave for 5 min. Stop Evacuation Check and correct pipe joints Airtight Check Abnormal indication of manifold gauges Refrigerant Charge Gas Leak Check Refrigerant Charge Fill refrigerant in gas state until gauge pressure reads 1 kglcm2 AC–6 AIR CONDITIONING SYSTEM – GENERAL DESCRIPTION CAUTION: • • Be sure to connect both the high and low pressure quick–connectors onto the A/C system when eva– cuating. If only one side is connected, the system would be open to atmosphere through the other connector, making it impossible to maintain vacuum. Be sure to turn off the manifold gauge valve imme– diately after evacuating the system. Then you may switch off the vacuum pump. PRECAUTIONS WHEN CHARGING REFRIGERANT 1. 2. 3. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system oil lubrication will be insufficient and compres– sor burnout may occur, so take care to avoid this. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILST COMPRESSOR IS OPERATING If the high pressure valve is opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the low pres– sure valve only. BE CAREFUL NOT TO OVERCHARGE WITH RE– FRIGERANT IN SYSTEM If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc. ELECTRICAL PARTS Before removing and inspecting the electrical parts, set the ignition switch to the LOCK position and disconnect the negative (–) terminal cable from bat– tery. CAUTION: Work must be started after 90 seconds from the time the Ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is discon– nected from the battery. AC–7 AIR CONDITIONING SYSTEM – GENERAL DESCRIPTION SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to deploy, possibly leading to a serious acci– dent. During removal or installation of the parts and the yellow wire harness and connector for the airbag is necessary, refer to the precautionary notices in the RS section before performing the operation. CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is discon– nected from the battery. AC–8 AIR CONDITIONING SYSTEM DESCRIPTION PARTS LOCATION – DESCRIPTION AC–9 AIR CONDITIONING SYSTEM – DESCRIPTION AC–10 AIR CONDITIONING SYSTEM – DESCRIPTION ELECTRICAL WIRING DIAGRAM (Lever Type On 5S–FE Engine Model) AC–11 AIR CONDITIONING SYSTEM – DESCRIPTION AC–12 AIR CONDITIONING SYSTEM – DESCRIPTION (Push Button Type On 5S–FE Engine Model) AC–13 AIR CONDITIONING SYSTEM – DESCRIPTION AC–14 AIR CONDITIONING SYSTEM – DESCRIPTION (Lever Type On 1 MZ–FE Engine Model) AC–15 AIR CONDITIONING SYSTEM – DESCRIPTION AC–16 AIR CONDITIONING SYSTEM – DESCRIPTION (Push Button Type On 1 MZ–FE Engine Model) AC–17 AIR CONDITIONING SYSTEM – DESCRIPTION AC–18 AIR CONDITIONING SYSTEM DAMPERS POSITION – DESCRIPTION AC–19 AIR CONDITIONING SYSTEM – PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) 07110–58060 Air Conditioner Service Tool Set (07117–58060) Refrigerant Drain Service Valve (07117–58070) T–Joint (07117–58080) Quick Coupler Discharge (diam. 16 mm) Suction (diam. 13 mm) (07117–58090) Quick Coupler (07117–78050) Refrigerant Charging Gauge (07117–88060) Refrigerant Charging Hose (07117–88070) Refrigerant Charging Hose (07117–88080) Refrigerant Charging Nose 07112–66040 Magnetic Clutch Remover 07112–76060 Magnetic Clutch Stopper 07114–84020 Snap Ring Pliers 07116–38360 Gas Leak Detector Assembly Discharge (Red) Suction (Blue) Utility (Green) AC–20 AIR CONDITIONING SYSTEM – PREPARATION RECOMMENDED TOOL 09082–00050 TOYOTA Electrical Tester Set LUBRICANT Item Capacity Classification ND–OIL 8 or equivalent Compressor oil When replacing receiver 10 cc (0.34 fl.oz.) When replacing condenser 40 cc (1.4 f I.oz.) When replacing evaporator 40 cc (1.4 fl.oz.) When replacing compressor 140 cc (4.9 fl.oz.) AC–21 AIR CONDITIONING SYSTEM – USE OF MANIFOLD GAUGE SET USE OF MANIFOLD GAUGE SET MANIFOLD GAUGE SET INSTALLATION 1. CONNECT CHARGING HOSES TO MANIFOLD GAUGE SET Tighten the nuts by hand. 2. CONNECT QUICK CONNECTORS TO CHARGING HOSES Tighten the nuts by hand. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET REMOVE CAPS FROM SERVICE VALVES ON RE– FRIGERANT LINE CAUTION: Do not connect the wrong hoses. 3. 4. 5. CONNECT QUICK CONNECTORS TO SERVICE VALVES HINT: Push the quick connector onto the service valve, then slide the sleeve of the quick connector downward to lock it. MANIFOLD GAUGE SET REMOVAL 1. 2. 3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET DISCONNECT QUICK CONNECTORS FROM SER– VICE VALVES ON REFRIGERANT LINE HINT: Slide the sleeve of the quick connector upward to unlock the connector and remove it from the ser– vice valve. INSTALL CAPS TO SERVICE VALVES ON REFRIG– ERANT LINE AC–22 AIR CONDITIONING SYSTEM – TROUBLESHOOTING TROUBLESHOOTING Use the table below to help you find the cause of problem. The numbers indicate the priority of the likely cause of the problem. Check each rt in order. If necessary, replace these parts. No blower operation No blower control No air flow mode control No air inlet control Insufficient flow of cool air Insufficient flow of warm air No cool air comes out Cool air comes out intermittently Cool air comes out only at high engine speed Insufficient cooling No warm air comes out Air temp. control not functioning No engine idle up when A/C switch on A/C Fan Relays Magnet Clutch Relay Revolution Detecting Sensor Evaporator Temp. Sensor Pressure Switch Fuse (A/C) AC–60 AC–62 AC–63 AC–63 AC–64 Fusible Link Inspect Drive Belt Tension Trouble Inspect Refrigeration System with Manifold Gauge Set Parts Name AC–29 AC–24 AC–30 Inspect Volume of Refrigerant See page Wiring or Wiring Connection Expansion Valve (Replace) Receiver Magnet Clutch Evaporator – Condenser Compressor A/C Amplifier A/C Control Assembly Condenser Fan Motor Blower Motor AC–59 AC–57 Air out let Servomotor Air Inlet Servomotor Blower Resistor AIR CONDITIONING SYSTEM TROUBLESHOOTING AC–23 AC–58 AC–55 AC–56 AC–67 AC–66 AC–36 AC–47 AC–49 AC–36 AC–45 AC–53 AC–24 AIR CONDITIONING SYSTEM – TROUBLESHOOTING REFRIGERANT SYSTEM INSPECTION WITH MANIFOLD GAUGE SET This is a method in which the trouble is located by using a manifold gauge set. (See ”USE OF MANIFOLD GAUGE SET” on page AC–21) Read the manifold gauge pressure when the following conditions are established: (a) Temperature at the air inlet with the switch set at RECIRC is 30 – 35
C (86 – 95
F) (b) Engine running at 1,500 rpm (c) Blower speed control switch set at high (d) Temperature control set at max. cool HINT: It should be noted that the gauge indications may vary slightly due to ambient temperature conditions. 1. NORMALLY FUNCTIONING REFRIGERATION SYSTEM Gauge reading: Low pressure side: 0.15 – 0.25 MPa (1.5 – 2.5 kgf/cm’) High pressure side: 1.37 – 1.57 MPa (14 – 16 kgf/emt) AC–25 AIR CONDITIONING SYSTEM 2. – TROUBLESHOOTING MOISTURE PRESENT IN REFRIGERATION SYSTEM Condition: Periodically cools and then fails to cool • 3. Symptom seen in refrigeration system During operation, prea– sure on low pressure side sometimes becomes a vacuum and sometimes normal Probable cause • Moisture entered in re– • frigeration system freezes at expansion valve orifice and tempo– • rarily stops cycle, but normal state is restored after a time when the ice melts Diagnosis Remedy (1) Replace receiver/drier (2) Remove moisture in cycle through repeat– Moisture in refrigeration edly evacuating air system freezes at expan– (3) Charge new refrigerant sion valve orifice and to proper amount blocks circulation of re– frigerant Drier in oversaturated state INSUFFICIENT REFRIGERANT Condition: Insufficient cooling Symptom seen in refrigeration system • • • Pressure low on both low and high pressure sides Bubbles seen in sight glass continuously Insufficient cooling per– formance Probable cause • Gas leakage at some • place in refrigeration sys– tem • Diagnosis Remedy Insufficient refrigerant in (1) Check for gas leakage system with leak detector and repair if necessary 1 (2) Charge refrigerant to Refrigerant leaking proper arhount (3) If pressure indicated value is near 0 when connected to gauge, create the vacuum af– ter inspecting and re– pairing the location of the leak AC–26 AIR CONDITIONING SYSTEM 4. – TROUBLESHOOTING POOR CIRCULATION OF REFRIGERANT Condition: Insufficient cooling • • 5. Symptom seen in refrigeration system Pressure low on both • low and high pressure sides Frost on tubes from receiver to unit Probable cause Refrigerant flow ob– • structed by dirt in re– ceiver Diagnosis R e c e i v e r clogged Remedy • Replace receiver REFRIGERANT DOES NOT CIRCULATE Condition: Does not cool (Cools from time to time in some cases) • • Symptom seen in refrigeration system Vacuum indicated on • low pressure side, very low pressure indicated on high pressure side Frost or dew seen on • piping before and after receiver/drier or expan– sion valve Probable cause Refrigerant flow ob– • structed by moisture or dirt in refrigeration sys– tem Refrigerant flow ob– structed by gas leakage from expansion valve heat sensing tube Diagnosis Remedy Refrigerant does not cir– (1) Check heat sensing culate tube, expansion valve and EPR (2) Clean out dirt in expan– sion valve by blowing with air If not able to remove dirt, replace expansion valve (3) Replace receiver (4) Evacuate air and charge new refrigerant to proper amount. For gas leakage from heat sensing tube, re– place expansion valve. AC–27 AIR CONDITIONING SYSTEM 6. – TROUBLESHOOTING REFRIGERANT OVERCHARGE OR INSUFFICIENT COOLING OF CONDENSER Condition: Does not cool sufficiently Symptom seen in refrigeration system • • 7. Pressure too high on both low and high pressure sides No air bubbles seen through the sight glass even when the engine rpm is lowered. Probable cause • • Diagnosis Unable to develop suffi– • cient performance due to excessive refrigerant in system • .Insufficient cooling of condenser Remedy Excessive refrigerant in (1) Clean condenser cycle – refrigerant over– (2) Check fan motor oper– ation charged: (3) If (1) and (2) are in nor– Condenser cooling insuf– mal state, check ficient – condenser fins amount of refrigerant Charge proper amount clogged or fan motor of refrigerant faulty AIR PRESENT IN REFRIGERATION SYSTEM Condition: Does not cool down sufficiently • • • Symptom seen in refrigeration system Pressure too high on • both low and high pressure sides The low pressure piping is hot to the touch Bubbles seen in sight glass Probable cause Diagnosis Air entered in refrigera– • tion system • Remedy Air present in refrigera– (1) Check compressor oil tion system to see if dirty or insuffi– cient (2) Evacuate air and Insufficient vacuum charge new refrigerant purging AC–28 AIR CONDITIONING SYSTEM 8. – TROUBLESHOOTING EXPANSION VALVE IMPROPERLY MOUNTED/HEAT SENSING TUBE DEFECTIVE (OPENS TOO WIDE) Condition: Insufficient cooling Symptom seen in refrigeration system • • 9. Pressure too high on both low and high pressure sides Frost or large amount of dew on piping on low pressure side Probable cause • Trouble in expansion valve or heat sensing tube not installed cor– rectly Diagnosis • Excessive refrigerant in low pressure piping • Expansion valve opened too wide Remedy (1) Check heat sensing tube installed condition (2) If (1) is normal, check expansion valve Replace if’ defective DEFECTIVE COMPRESSION COMPRESSOR Condition: Does not cool Symptom seen in ref rigeration system • • Pressure too high on low pressure side Pressure too low on high pressure side Probable cause • Internal leak in compres– sor Diagnosis • Compression defective • Valve leaking or broken, sliding parts Remedy • Repair or replace com– pressor AC–29 AIR CONDITIONING SYSTEM – REFRIGERANT VOLUME REFRIGERANT VOLUME REFRIGERANT VOLUME INSPECTION 1. 2. RUN ENGINE AT IDLE SPEED OPERATE A/C AT MAXIMUM COOLING FOR A FEW MINUTES INSPECT AMOUNT OF REFRIGERANT OBSERVE THE SIGHT GLASS ON THE LIQUID TUBE. 3. Item Amount of refrigerant Symptom Bubbles present insight glass Insufficient’ No bubbles present in sight glass None, sufficient or too much No temperature difference between compressor inlet and outlet Empty or nearly empty Remedy (1) Check for gas lakage with gas leak tester and repair if necessary (2) Add refrigerant until bubbles dis– apear Refer to items 3 and 4 (1) Check for gas leakage with gas lea– ktester and repair if necessary (2) Add refrigerant until bubbles disap– pear Temperature between compressor inlet Proper or too much and outlet is noticeably different Refer to items 5 and 6 Immediately after air conditioning is turned off, refrigerant in sight glass stays clear (1) Discharge refrigrant (2)Evacuate air and charge proper amo– unto of purified refrigerant When air conditioning is turned off, re– frigerant foams and then stay clear Too much Proper *: Bubbles in the sight glass with ambient temperatu– ers higher can be considered normal if cooling is suff icient. REFRIGERANT CHARGE VOLUME Specified amount: 850 ± 50 g (29.98 ±1.76 oz) AC–30 AIR CONDITIONING SYSTEM – DRIVE BELT TENSION DRIVE BELT TENSION DRIVE BELT TENSION INSPECTION 1. INSPECT DRIVE BELT’S INSTALLATION CONDI– TION Check that the drive belt fits properly in the ribbed grooves. 2. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt ten– sion. Belt tension gauge: Nippondenso BTG–20 (95506–00020) or Borroughs No. BT–33–73F Drive belt tension: 5S– FE: New belt 165 ± 26 Ibf Used belt 110 ± 11 lbf 1 MZ–FE: New belt 165 ± 26 lbf Used belt 88 ± 22 lbf HINT: • ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. • ”Used belt” refers to a belt which has beenused on a running engine for 5 minutes or more. • After installing the drive belt, check that it fits properly in the ribbed grooves. IDLE–UP SPEED IDLE UP SPEED INSPECTION 1. 2. WARM UP ENGINE INSPECT IDLE SPEED 5S– FE: Magnet clutch condition Standard idle speed (rpm) No engaged Approx. 750 Engaged Approx. 850 1 MZ – FE: Magnet clutch condition Standard idle speed (rpm) No engaged Approx. 700 Engaged Approx. 700 AC–31 AIR CONDITIONING SYSTEM – REFRIGERANT LINES REFRIGERANT LINES TIGHTENING TORQUE OF REFRIGERATION LINES ON–VEHICLE INSPECTION 1. 2. INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak tester, check for leakage of refriger– ant. AC–32 AIR CONDITIONING SYSTEM – REFRIGERANT LINES REFRIGERANT LINES REPLACEMENT 1. 2. 3. DISCHARGE REFRIGERANT IN REFRIGERATION SYSTEM (See page AC–21) REPLACE FAULTY TUBE OR HOSE HINT: Cap the open fittings immediately to keep mois– ture or dirt out of the system. TORQUE CONNECTIONS TO SPECIFIED TORQUE NOTICE: Connections should not be torque tighter than the specified torque. 4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount: 850 ±50g (29.98 ±1.76 oz) 5. 6. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak tester, check for leakage of refriger– ant. INSPECT AIR CONDITIONING OPERATION AC–33 AIR CONDITIONING SYSTEM – AIR CONDITIONING UNIT AIR CONDITIONING UNIT A/C UNIT REMOVAL 1. 2. 3. 4. 5. 6. DISCHARGE REFRIGERANT FROM REFRIGERA– TION SYSTEM (See page AC–21) DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. DISCONNECT WATER VALVE CONTROL CABLE FROM WATER VALVE DISCONNECT WATER HOSES FROM HEATER RA– DIATOR PIPES REMOVE INSTRUMENT PANEL AND REINFORCE– MENT (See page BO–108) REMOVE BLOWER UNIT (See page AC–35) 7. DISCONNECT LIQUID AND SUCTION TUBE FROM BLOCK JOINT Remove 2 bolts and both tubes. 8. REMOVE REAR AIR DUCTS Remove the clip and the air duct. 9. REMOVE HEATER PROTECTOR Remove the 2 clips and the heater protector. AC–34 AIR CONDITIONING SYSTEM – AIR CONDITIONING UNIT 10. REMOVE A/C UNIT (a) Disconnect connectors from the unit. (b) Remove the 3 nuts and the A/C unit. A/C UNIT INSTALLATION 1. (a) (b) 2. 3. 4. INSTALL A/C UNIT Install the A/C unit with the 3 nuts. Connect connectors. INSTALL HEATER PROTECTOR INSTALL REAR AIR DUSTS CONNECT LIQUID AND SUCTION TUBE TO BLOCK JOINT 5. INSTALL BLOWER UNIT 6. INSTALL INSTRUMENT PANEL AND REINFORCE– MENT 7. CONNECT WATER HOSES TO HEATER RADIATOR PIPES 8. CONNECT WATER VALVE CONTROL CABLE TO WATER VALVE (See step 3 on page AC–33) 9. REFILL WITH ENGINE COOLANT 10. EVACUATE AIR FROM REFRIGERATION SYSTEM 11. CHARGE SYSTEM WITH REFRIGERANT AND IN– SPECT FOR LEAKAGE OF REFRIGERANT Specified amount: 850 ±50 g (29.98 ±1.76 oz) AC–35 AIR CONDITIONING SYSTEM – BLOWER UNIT BLOWER UNIT BLOWER UNIT REMOVAL 1. 2. REMOVE GLOVE COMPARTMENT (See page BO–108) REMOVE ECU AND ECU BRACKET 3. REMOVE CONNECTOR BRACKET (a) Disconnect the connector from the connector brack– et. (b) Remove the 2 screws and the bracket. 4. (a) (b) (c) REMOVE BLOWER UNIT Disconnect the connector from the blower unit. Disconnect the air inlet damper control cable. Remove the 3 screws, nut and the blower unit. BLOWER UNIT INSTALLATION 1. INSTALL BLOWER UNIT (a) Install the blower unit with the 3 screws and the nut. (b) Connect the air inlet damper control cable to the blower unit. (c) Connect the connector. 2. INSTALL CONNECTOR BRACKET 3. INSTALL ECU BRACKET AND ECU 4. INSTALL GLOVE COMPARTMENT AC–36 AIR CONDITIONING SYSTEM – COMPRESSOR COMPRESSOR ON–VEHICLE INSPECTION Magnet Clutch: 1. MAKE THE FOLLOWING VISUAL CHECKS: Leakage of grease from the clutch bearing. Signs of oil on the pressure plate or rotor. Repair or replace, as necessary. 2. INSPECT MAGNET CLUTCH BEARING FOR NOISE (a) Start engine. (b) Check for abnormal noise from near the compressor when the A/C switch is OFF. If abnormal noise is being emitted, replace the mag– netic clutch. 3. INSPECT MAGNET CLUTCH (a) Disconnect the connector from the magnet clutch. (b) Connect the positive (+) lead from the battery to the terminal on the magnetic clutch connector and the negative (–) lead to the body ground. (c) Check that the magnet clutch is energized. If operation is not as specified, replace the magnet clutch. Compressor: 1. 2. 3. 4. 5. 6. INSTALL MANIFOLD GAUGE SET (See page AC–21) START ENGINE INSPECT COMPRESSOR FOR METALLIC SOUND Check that there is a metallic sound from the com– pressor when the A/C switch is turn on. If metallic sound is heard, replace the compressor assembly. INSPECT PRESSURE OF REFRIGERATION SYSTEM See “Refrigerant System Inspection with Manifold Gauge Set” on page AC–24. STOP ENGINE INSPECT VISUALLY FOR LEAKAGE OF REFRIGER– ANT FROM SAFETY SEAL If there is any leakage, replace the compressor assem– bly. AC–37 AIR CONDITIONING SYSTEM – COMPRESSOR COMPRESSOR REMOVAL 5S–FE Engine Model: 1. 2. 3. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX 10 MINUTES STOP ENGINE DISCONNECT NEGATIVE (–) CABLE FROM BAT– TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 4. DISCHARGE REFRIGERANT FROM REFRIGERA– TION SYSTEM (See page AC–21) 6. DISCONNECT DISCHARGE HOSE AND SUCTION HOSE FROM COMPRESSOR 7. DISCONNECT CONNECTOR FROM MAGNET CLUTCH 8. REMOVE COMPRESSOR (a) Loosen the drive belt. (b) Remove 3 bolts and compressor. AC–38 AIR CONDITIONING SYSTEM – COMPRESSOR COMPRESSOR REMOVAL 1 MZ–FE Engine Model: 1. 2. 3. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX 10 MINUTES STOP ENGINE DISCONNECT NEGATIVE (–) CABLE FROM BAT– TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. AC–39 AIR CONDITIONING SYSTEM 4. 5. 6. 7. – COMPRESSOR DISCHARGE REFRIGERANT FROM REFRIGERA– TION SYSTEM (See page AC–21) DISCONNECT DISCHARGE HOSE AND SUCTION HOSE FROM COMPRESSOR DISCONNECT CONNECTOR FROM MAGNET CLUTCH REMOVE DRIVE BELT Loosen the pivot bolt and adjusting lock bolt and remove the drive belt. 8. REMOVE COMPRESSOR (a) Remove 2 nuts and 2 bolts. (b) Remove the compressor. AC–40 AIR CONDITIONING SYSTEM – COMPRESSOR MAGNET CLUTCH DISASSEMBLY 1. REMOVE PRESSURE PLATE (a) Using SST and socket wrench, remove the shaft bolt. SST 07112 – 76060 (b) Install a SST on the pressure plate. SST 07112–66040 AC–41 AIR CONDITIONING SYSTEM (c) – COMPRESSOR Using SST and socket wrench, remove the pressure plate. SST 07112–76060 (d) Remove the shims from the pressure plate. 2. REMOVE ROTOR (a) Using SST, remove the snap ring. SST 07114–84020 CAUTION: Do not spread the point of SST widely. Max width: 23.1 mm (b) Using a plastic hammer, tap the rotor off the shaft. NOTICE: Be careful not to damage the pulley when tapp– ing on the rotor. 3. REMOVE STARTER (a) Disconnect the stator lead wire from the compressor housing. AC–42 AIR CONDITIONING SYSTEM – COMPRESSOR (b) Using a SST, remove the snap ring. SST 07114–84020 (c) Remove the stator. MAGNET CLUTCH ASSEMBLY 1. INSTALL STATOR (a) Install the stator on the compressor. (b) Using SST, install the new snap ring. SST 07114 –84020 NOTICE: The snap ring should be installed so that its beveled side faces up. AC–43 AIR CONDITIONING SYSTEM (c) – COMPRESSOR Using SST and torque wrench, fasten the magnet clutch lead wire to the cylinder block. Torque: 3.4 N–m (35 kgf.cm, 30 in.–lbf) SST 07110–61050 2. INSTALL ROTOR (a) Install the rotor on the compressor shaft. (b) Using SST, install the new snap ring. SST 07114–84020 CAUTION:Do not spread the point of SST widely. Max width: 23.1 mm NOTICE: The snap ring should be installed so that its beveled side faces up. 3. INSTALL PRESSURE PLATE (a) Put the shims on the pressure plate. (b) Using SST and torque wrench, install the shaft bolt. SST 07112–76060 Torque: 13 N–m (135 kgf–cm, 10 ft–lbf) AC–44 AIR CONDITIONING SYSTEM – COMPRESSOR 4. CHECK CLEARANCE OF MAGNET CLUTCH (a) Set the dial – gauge to the pressure plate of the magnet clutch. (b) Connect the magnet clutch lead wire to the positive (+) terminal of the battery. (c) Check the clearance between the pressure plate and rotor, whenconnect the negative (–) terminal of the battery. Standard clearance: 0.5 ± 0.15 mm (0.020 ± 0.059 in.) If the clearance is not within standard clearance, adjust the clearance using shims to obtain the stand– ard clearance. COMPRESSOR INSTALLATION 1. INSTALL COMPRESSOR (a) Install compressor with 4 bolts. Torque: 25 N–m (250 kgf–cm, 18 ft–lbf) (b) (c) 2. 3. Install drive belt. Inspect drive belt tension. CONNECT CONNECTOR TO MAGNET CLUTCH CONNECT DISCHARGE HOSE AND SUCTION HOSE TO COMPRESSOR NOTICE: Hoses should be connected immediately after the caps have been removed. Torque: 25 N–m (250 kgf–cm, 18 ft–lbf) 4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount: 5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak tester, check for leakage of refriger– ant. If there is leakage, check the tightening torque at the joints. CONNECT NEGATIVE (–) CABLE TO BATTERY INSPECT A/C OPERATION 850 ±50 g (29.98 ±1.76 oz) 6. 7. AC–45 AIR CONDITIONING SYSTEM – RECEIVER RECEIVER ON–VEHICLE INSPECTION INSPECT FITTINGS FOR LEAKAGE Using a gas leak tester, check for leakage. If there is leakage, check the tightening torque at the joints. RECEIVER REMOVAL 1. DICHARGER REFRIGERANT FROM REFRIGERA– TION SYSTEM (See page AC–21) 2. REMOVE 2 LIQUID TUBES FROM RECEIVER Remove the 2 bolts and the both tubes from the receiver. 3. REMOVE RECEIVER FROM RECEIVER HOLDER Remove the bolt, then remove the receiver from re– ceiver holder. NOTICE: Cap the open fittings immediately to keeps moi– sture out of the system. AC–46 AIR CONDITIONING SYSTEM – RECEIVER RECEIVER INSTALLATION 1. 2. INSTALL RECEIVER INTO RECEIVER HOLDER Install the receiver into the receiver, holder with the bolt. INSTALL 2 LIQUID TUBES TO RECEIVER Install 2 liquid tubes to the receiver with 2 bolts. Torque: 5.5 N–m (55 kgf–cm, 48 in.–lbf) NOTICE: Do not remove the caps until the tubes are connected. 3. REPLENISH COMPRESSOR OIL IF RECEIVER HAS BEEN REPLACED Add 15 cc (0.5 fl.oz.) Compressor oil: 4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount: ND OIL 8 or equivalent 850 ±50 g (29.98 ±1.76 oz) 5. 6. INSPECT FOR LEAKAGE OF REFRIGERANT INSPECT A/C OPERATION AC–47 AIR CONDITIONING SYSTEM – CONDENSER CONDENSER ON–VEHICLE INSPECTION 1. INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE If the fins are clogged, wash them with water and dry with compressed air. NOTICE: Be careful not to damage the fins. 2. If the fins are bent, straighten them with a screwdriver or pliers. INSPECT CONDENSER AND FITTINGS FOR LEAK– AGE Using a gas leak tester, check for leakage. If there is leakage, check the tightening torque at the joints. CONDENSER REMOVAL 1. 2. 3. 4. 5. DISCHAGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC–21) REMOVE UPPER COVER REMOVE COOLING FAN (See page EG–351) REMOVE UPPER SUPPORT Remove the 2 bolts and 2 upper supports. REMOVE LIQUID TUBES Remove the 2 bolts and 2 tubes. NOTICE: Cap the open fittings immediately to keep mois– ture out of the system. 6. REMOVE HEADLIGHTS ON THE BOTH SIDES AC–48 AIR CONDITIONING SYSTEM 7. – CONDENSER REMOVE CONDENSER Remove the 2 bolts and lean the radiator backward, then remove the cond enser. CONDENSER INSTALLATION 1. 2. INSTALL CONDENSER Install the condenser with the 2 bolt. INSTALL LIQUID TUBES Install both tubes with the 2 bolts. Specified torque: 9.8 N–m (100 kgf–cm, 7 ft–lbf) NOTICE: Do not remove caps until the tube is installed. 3. 4. INSTALL COOLING FAN REPLENISH COMPRESSOR OIL IF CONDENSER HAS BEEN REPLACED Add 40 cc (1.4 fl.oz.) Compressor Oil: ND OIL 8 or equivalent 5. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount: 850 ±50g (33.51 ±1.76 oz) 6. 7. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak tester, check for leakage of refriger– ant. INSTALL REMOVAL PARTS Install the removal parts in reverse order of removal procedure. AC–49 AIR CONDITIONING SYSTEM – EVAPORATOR EVAPORATOR EVAPORATOR REMOVAL 1. 2. DISCHARGE REFRIGERANT FROM REFRIGERA– TION SYSTEM (See page AC–21) REMOVE BLOWER UNIT (See page AC–35) 3. REMOVE EVAPORATOR COVER (a) Remove 2 bolts for the liquid and suction tube. (b) Remove 8 screws and evaporator cover. 4. REMOVE EVAPORATOR (a) Pull and remove the evaporator. (b) Remove 2 bolts using a hexagon wrench and separate the evaporator and expansion valve. EVAPORATOR INSPECTION 1. INSPECT FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. NOTICE: Never use water to clean the evaporator. 2. INSPECT FITTINGS FOR CRACKS OR SCRATCHES Repair as necessary. AC–50 AIR CONDITIONING SYSTEM – EVAPORATOR EVAPORATOR INSTALLATION 1. INSTALL REMOVAL PARTS Install the removal parts in reverse order of removal procedure. HINT: The tightening torque for the bolt used to install the expantion valve on the evaporator is shown below. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) The tightening torque for the bolts used to install the liquid and suction tube is shown below. Torque: 9.8 N–m (100 kgf–cm, 7 ft–lbf) 2. REPLENISH COMPRESSOR OIL IF EVAPORATOR HAS BEEN REPLACED Add 40 cc (1.4 fl.oz) Compressor oil: ND OIL 8 or equivalent 3. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount: 850 ± 50g (29.98 ±1.76 oz) 4. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak tester, check for leakage of refriger– ant. AC–51 AIR CONDITIONING SYSTEM – HEATER RADIATOR HEATER RADIATOR HEATER RADIATOR REMOVAL 1. REMOVE HEATER PROTECTOR Remove the 2 clips and the heater protector. 2. REMOVE HEATER RADIATOR (a) Remove the 3 screws and the 3 clamps. (b) Disconnect the heater pipes. (c) Pull the heater radiator out. HEATER RADIATOR INSPECTION If the fin are clogged, clean them with commpressed air. HEATER RADIATOR INSTALLATION 1. (a) (b) (c) 2. INSTALL HEATER RADIATOR TO A/C UNIT Put the radiator in the A/C unit. Connect teh heater pipes. Install the 3 clamps with 3 screws. INSTALL HEATER PROTECTOR AC–52 AIR CONDITIONING SYSTEM – WATER VALVE WATER VALVE WATER VALVE REMOVAL 1. 2. 3. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. DISCONNECT WATER VALVE CONTROL CABLE FROM WATER VALVE DISCONNECT WATER HOSE FROM WATER VALVE 4. REMOVE WATER VALVE (a) Disconnect the water hose from the heater radiator pipe. (b) Remove the bolt and the water valve WATER VALVE INSTALLATION 1. INSTALL WATER VALVE (a) Push the water hose onto the heater radiator pipe as far as rigs on the pipe and install the hose clip. (b) Install water valve with the bolt. 2. CONNECT HEATER HOSE TO WATER VALVE 3. CONNECT WATER VALVE CONTROL CABLE TO WATER VALVE (a) Set the temperature control switch to ”COOL”. (b) Set the water valve lever to ”COOL”, install the control cable and lock the clamp. HINT: Lock the clamp while lightly pushing the outer cable in the direction shown by the arrow. AC–53 AIR CONDITIONING SYSTEM – EXPANSION VALVE EXPANSION VALVE ON–VEHICLE INSPECTION 1. 2. 3. 4. CHECK QUANTITY OF GAS DURING REFRIGERA– TION CYCLE INSTALL MANIFOLD GAUGE SET RUN ENGINE Run the engine at 1,500 rpm for at least 5 minutes. Then check that the high pressure reading is 1.37 – 1.53 MPa (14 – 16 kgf/cm2, 199 – 228 psi). CHECK EXPANSION VALVE If the expansion valve is faulty, the low pressure reading will drop to 0 kPa (0 kgf/cm2, 0 psi). HINT: When the low pressure drops to 0 kPa (0 kgf/ cm2, 0 psi), feel the receiver’s IN and OUT sides for no temperature difference. EXPANSION VALVE REMOVAL 1. 2. REMOVE EVAPORATOR (See page AC–50) REMOVE EXPANSION VALVE (See page AC–51) EXPANTION VALVE INSTALLSION 1. 2. INSTALL EXPANSION VALVE (See page AC–51) INSTALL EVAPORATOR (See page AC–51) AC–54 AIR CONDITIONING SYSTEM – AIR SWITCHING VALVE (ASV) AIR SWITCHING VALVE (ASV) VACUUM HOSE CIRCUIT (5S–FE ENGINE MODEL) ASV INSPECTION (5S–FE ENGINE MODEL) 1. CHECK VACUUM CIRCUIT CONTINUITY IN ASV BY BLOWING AIR INTO PIPES (a) Connect the ASV terminals to the battery terminals as illustrated. (b) Blow into pipe ”A” and’ check that air comes out of pipe ”B”. (c) Disconnect the battery. (b) Blow into pipe ”A” and check that air does not come out of pipe ”B”. If a problem is bound, replace the ASV. 2. CHECK FOR SHORT CIRCUIT Using an ohmmeter, check that there is no continuity between each terminal and the ASV. If there is continuity, replace the ASV. 3. CHECK FOR OPEN CIRCUIT Using an ohmmeter, measure the resistance between the 2 terminals. Resistance: 30 – 34 0 at 20° C (68° F) If resistance value is not as specified, replace the ASV. AC–55 AIR CONDITIONING SYSTEM – BLOWER MOTOR BLOWER MOTOR BLOWER MOTOR REMOVAL 1. 2. REMOVE INSTRUMENT LOWER PANEL AND UNDER COVER NO. 2 (See page BO–108) REMOVE CONNECTOR BRACKET Remove the 2 screws and the bracket 3. REMOVE MOTOR (a) Disconnect the connector. (b) Remove the 3 screws and the motor. BLOWER MOTOR INSPECTION INSPECT BLOWER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, then check that the motor operation is smooth. BLOWER MOTOR INSTALLATION 1. (a) (b) 2. 3. INSTALL MOTOR Install the motor with the 3 screws. Connect the connector. INSTALL CONNECTOR BRACKET INSTALL INSTRUMENT LOWER PANEL AND UNDER COVER NO. 2 AC–56 AIR CONDITIONING SYSTEM – CONDENSER FAN MOTOR CONDENSER FAN MOTOR CONDENSER FAN MOTOR INSPECTION 5S–FE ENGINE MODEL: 1. 2. DISCONNECT CONNECTOR INSPECT CONDENSER FAN MOTOR Connect positive (+) lead from battery and negative (–) lead to terminals, then check that the condenser fan motor operates smoothly. Standard current: 6.7±1 (A) If current value is not as specified, replace the con– denser fan motor. AC–57 AIR CONDITIONING SYSTEM – AIR INLET SERVOMOTOR AIR INLET SERVOMOTOR AIR INLET SERVOMOTOR REMOVAL 1. 2. REMOVE GLOVE COMPARTMENT (See page BO–108) REMOVE ECU AND ECU BRACKET 3. REMOVE SERVOMOTOR (a) Disconnect the connector. (b) Remove the 2 screws and the servomotor. AIR INLET SERVOMOTOR INSPECTION INSPECT SERVOMOTOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the arm rotates to the ”FRESH” side smoot– hly. (b) Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 3, check that the arm rotates to the ”RECI RC” side smo– othly. If operation is not as specified, replace the servo motor. AIR INLET SERVOMOTOR INSTALLATION 1. (a) (b) 2. 3. INSTALL SERVOMOTOR Install the servomotor with the 2 screws. Connect the connector. INSTALL ECU AND ECU BRACKET INSTALL GLOVE COMPARTMENT AC–58 AIR CONDITIONING SYSTEM – AIR OUTLET SERVOMOTOR AIR OUTLET SERVOMOTOR AIR OUTLET SERVOMOTOR REMOVAL 1. 2. REMOVE INSTRUMENT LOWER FINISH PANEL AND AIR DUCT (See page BO–108) REMOVE AIR DUCT NO. 2 3. REMOVE SERVOMOTOR (a) Disconnect the connector. (b) Remove the 2 screws and the servomotor. AIR OUTLET SERVOMOTOR INSPECTION INSPECT SERVOMOTOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 6 and the negative (–) lead to terminal 7. (b) Connect the negative (–) lead from the battery to each terminal and check that the arm rotates to each position as shown below. Connected terminal Position D EF FOOT/DEF FOOT B/L FACE If operation is not as specified, replace the servomo– tor. AIR OUTLET SERVOMOTOR INSTALLATION 1. (a) (b) 2. 3. INSTALL SERVOMOTOR Install the servomotor with 2 screws. Connect the connector INSTALL HEATER DUCT INSTALL LOWER FINISH PANEL AC–59 AIR CONDITIONING SYSTEM – BLOWER RESISTOR BLOWER RESISTOR BLOWER RESISTOR REMOVAL 1. REMOVE INSTRUMENT LOWER FINISH PANEL (See page BO–108) 2. REMOVE BLOWER RESISTOR (a) Disconnect the connector from the resistor. (b) Remove the 2 screws and the resistor. BLOWER RESISTOR INSPECTION INSPECT BLOWER RESISTOR CONTINUITY Continuity Condition Constant Tester connectoin to terminal number 1–2–3–6 Specified value Continuity If continuity is not as specified, replace the blower resistor. Condition Tester connectoin to terminal number Constant t –2–3–5–6 Specified value Continuity If continuity is not as specified, replace the blower resistor. BLOWER RESISTOR INSTALLATION 1. (a) (b) 2. INSTALL BLOWER RESISTOR Install the resistor with the 2 screws. Connect the connector to the resistor. INSTALL INSTRUMENT LOWER FINISH PANEL AC–60 AIR CONDITIONING SYSTEM – PRESSURE SWITCH PRESSURE SWITCH ON–VEHICLE INSPECTION 1. 3. INSTALL MANIFOLD GAUGE SET (See page AC–21) DISCONNECT CONNECTOR FROM PRESSURE SWITCH RUN ENGINE AT APPROX. 2000 RPM 4. INSPECT PRESSURE SWITCH OPERATION 2. Magnet Clutch Control: (a) Connect the positive (+) lead from the ohmmeter to terminal 4 and negative (–) lead to terminal 1. (b) Check continuity between terminals when refrigerant pressure is changed, as shown. If operation is not as specified, replace the pressure switch. Cooling Fan Control: (a) Connect the positive (+) lead from the ohmmeter to terminal 2 and negative (–) lead to terminal 3. (b) Check continuity between terminals when refrigerant pressure is changed, as shown. If operation is not as specified, replace the pressure switch. 5. STOP ENGINE AND REMOVE MANIFOLD GAUGE SET 6. CONNECT CONNECTOR TO PRESSURE SWITCH AC–61 AIR CONDITIONING SYSTEM – PRESSURE SWITCH PRESSURE SWITCH REMOVAL 1. DISCHARGE REFRIGERANT IN REFRIGERATION SYSTEM 2. REMOVE PRESSURE SWITCH (a) Disconnect the connector. (b) Remove the pressure switch from the liquid tube. HINT: Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube, and remove the switch. PRESSURE SWITCH INSTALLATION 1. INSTALL PRESSURE SWITCH (a) Install the pressure switch to the liquid tube. Torque: 9.8 N–m (100 kgf–cm, 7 ft–lbf) HINT: Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube, and install the switch. (b) Connect the connector. 2. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount: 850 ±50 g (29.98 ±1.76 oz) 3. 4. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak tester, check for leakage of refriger– ant from the pressure switch mount. INSPECT A/C OPERATION AC–62 AIR CONDITIONING SYSTEM – EVAPORATOR TEMPERATURE SENSOR EVAPORATOR TEMPERATURE SENSOR EVAPORATOR TEMPERATURE SENSOR REMOVAL REMOVE EVAPORATOR TEMPERATURE SENSOR Remove the screw and the evaporator temperature sensor (thermistor). EVAPORATOR TEMPERATURE SENSOR INSPECTION Check resistance between terminals of evaporator temperature sensor (thermistor) connector at each temperature. Resistance: at 0
C (32
F): 4.6 – 5.1 k
at 15
C (59
F): 2.1 – 2.6 k
In addition as temperature increases, the resistance decreases gradually. EVAPORATOR TEMPERATURE SENSOR INSTALLATION INSTALL EVAPORATOR TEMPERATURE SENSOR Install evaporator temperature sensor in reverse order of removal procedure. AC–63 AIR CONDITIONING SYSTEM – REVOLUTION DETECTING SENSOR REVOLUTION DETECTING SENSOR ON–VEHICLE INSPECTION 1. DISCONNECT NEGATIVE (–) CABLE FROM BAT– TERY CAUTION: Work must be started after 90 seconds from the time the ignition swithch is turned “LOCK” position and the negative (–) terminal cable is disconnected from the battery. 2. 3. DISCONNECT CONNECTOR OF REVOLUTION DET– ECTING SENSOR INSPECT REVOLUTION DETECTING SENSOR Check the resistance between terminals 1 and 2 of the sensor. Specified resistance: 5S–FE: 165 – 205
at 20
C (68
F) 1 MZ– FE: 65 – 125
at 20
C (68
F) If the resistance value is not as specified, replace the revolution detecting sensor. REVOLUTION DETECTING SENSOR REMOVAL 1. REMOVE COMPRESSOR (See page AC–37) 2. REMOVE REVOLUTION DETECTING SENSOR (a) Remove 2 bolts. (b) Remove the revolution detecting sensor. REVOLUTION DETECTING SENSOR INSTALLATION 1. INSTALL REVOLUTION DETECTING SENSOR Using a torque wrench, tighten the bolts. Torque:6 N–m (60 kgf–cm, 4 ft–lbf) 2. INSTALL COMPRESSOR (See page AC–46) AC–64 AIR CONDITIONING SYSTEM – RELAY RELAY RELAYS REMOVAL 1. DISCONNECT NEGATIVE (–) CABLE FROM BAT– TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE RELAYS RELAYS INSPECTION 1. INSPECT MAGNET CLUTCH RELAY CONTINUITY Condition Tester connection to terminal number Specified value Constant 1–4 Continuity 2 –3 Continuity Apply B + between terminals 1 and 4. 2. If continuity is not as specified, replace the relay. INSPECT A/C FAN RELAY NO. 2 CONTINUITY 5S–FE Engine Model: Condition Constant Apply6 + between terminals 1 and 4. 3. Tester connection to terminal number Specified value 1 –4 3–5 Continuity 2–3 Continuity If continuity is not as specified, replace the relay. INSPECT A/C FAN RELAY NO. 3 CONTINUITY 5S–FE Engine Model: Condition Tester connection to terminal number Specified value Constant 1–4 Continuity 2–3 Continuity Apply B + between terminals 1 and 4. If continuity is not as specified, replace the relay. AC–65 AIR CONDITIONING SYSTEM 4. – RELAY INSPECT HEATER MAIN RELAY CONTINUITY Condition Constant Apply B + between terminals 1 and 3. Tester connection to terminal number Specified value 1–3 2–4 Continuity 4–5 Continuity If continuity is not as specified, replace the relay. RELAYS INSTALLATION 1. 2. INSTALL RELAYS CONNECT NEGATIVE (–) CABLE TO BATTERY AC–66 AIR CONDITIONING SYSTEM – AIR CONDITIONING AMPLIFIER AIR CONDITIONING AMPLIFIER A/C AMPLIFIER INSPECTION INSPECT AMPLIFIER CIRCUIT Disconnect the amplifier and inspect the connector on the wire harness side, as shown in the chart below. Test conditions • Ignition switch : ON • Temperature control dial : MAX COOL • Blower dial: HI Tester connection Condition Specified condition 5 – Ground Constant Continuity 9–13 Constant 1.5 k
at 20
C (68
F) 14–13 Constant Approx. 115
at 20
C (68
F) 12 – Ground Turn A/C switch ON Battery voltage 12– Ground Turn A/C switch OFF No voltage 2 – Ground Refrigerant pressure: 196 – 3140 kPa Battery voltage 2 – Ground Refrigerant pressure: less than 196 kPa or more than 3140 kPa No voltage 10 – Ground Turn A/C switch ON Battery voltage 10 – Ground Turn A/C switch OFF No voltage 8 – Ground Turn A/C switch ON Battery voltage 8 – Ground Turn A/C switch OFF No voltage If circuit is not as specified, replace the amplifier. AC–67 AIR CONDITIONING SYSTEM – AIR CONDITIONING CONTROL ASSEMBLY AIR CONDITIONING CONTROL ASSEMBLY A/C CONTROL ASSEMBLY REMOVAL (See page BO–108) A/C CONTROL ASSEMBLY INSPECTION (ROTARY SWITCH AND PUSH BUTTON TYPE) 1. INSPECT A/C INDICATOR (a) Connect the positive (+) lead from the battery to terminal A–12 and the negative (–) lead to terminal A–4. (b) Push the A/C button in and check that the indicator light up. If operation is not as specified, replace the A/C con– trol assembly. 2. INSPECT MODE INDICATOR (a) Connect the positive (+) lead from the battery to terminal A–12 and the negative (–) lead to terminal A–1. (b) Push each of the mode bottons in and check that their indicators light up. If operation is not as specified, replace the A/C con– trol assembly. AC–68 AIR CONDITIONING SYSTEM – AIR CONDITIONING CONTROL ASSEMBLY 3. INSPECT AIR INLET INDICATOR (a) Connect the positive (+) lead from the battery to terminal A– 12 and the negative (–) lead to terminal A–1. (b) Check that the FRESH and RECIRC indicators light up alternately each time the air inlet control switch button is pressed. If operation is not as specified, replace the A/C con– trol assembly. 4. INSPECT INDICATOR DIMMING OPERATION (a) Connect the positive (+) lead from the battery to terminal A– 12 and the negative (–) lead to terminal A –1. (b) Connect the positive (+) lead from the battery to terminal A–14 and check that the mode indicator dims. If operation is not as specified, replace the A/C con– trol assembly. 5. INSPECT A/C SWITCH CONTINUITY Switch position Tester connection to terminal number OFF Specified value No continuity A7 – A8 Continuity If continuity is not as specified, replace the A/C con– trol assembly. AC–69 AIR CONDITIONING SYSTEM 6. – AIR CONDITIONING CONTROL ASSEMBLY INSPECT MODE CONTROL SWITCH CONTINUITY Switch position FACE Tester connection to terminal number A11 –Al Specified value Continuity B/L A3 – A 1 Continuity FOOT A10 – A1 Continuity FOOT/ oeF A2 – A 1 Continuity D EF A9 – A 1 Continuity If continuity is not as specified, replace the A/C con– trol assembly. 7. INSPECT AIR INLET CONTROL SWITCH CONTINUITY Switch position Tester connectoin to terminal number Specified value RECIRC A5 – A 1 Continuity FRESH A6–A1 Continuity If continuity is not as specified, replace the A/C con– trol assembly. AC–70 AIR CONDITIONING SYSTEM 8. – AIR CONDITIONING CONTROL ASSEMBLY INSPECT BLOWER SPEED CONTROL SWITCH CON– TINUITY Terminal B–1 E–2 B–4 B–5 B–7 6–8 B–6 Switch position OFF If continuity is not as specified, replace the switch. AC–71 AIR CONDITIONING SYSTEM – AIR CONDITIONING CONTROL ASSEMBLY ROTARY SWITCH AND LEVER TYPE: 1. INSPECT A/C SWITCH CONTINUITY Switch position Tester connection to terminal number OFF. Specified value No continuity 2–5 Continuity If continuity is not as specified, replace the switch. 2. INSPECT MODE CONTROL SWITCH CONTINUITY Switch position Tester connection to terminal number Specified value FACE B/ L 1–8 Continuity 1–7 Continuity FOOT 1 –6 Continuity FOOT/ DEF 1–5 Continuity DEF 1–4 Continuity 3. If continuity is not as specified, replace the switch. INSPECT BLOWER SPEED CONTROL SWITCH CON– TINUITY AC–72 AIR CONDITIONING SYSTEM – AIR CONDITIONING CONTROL ASSEMBLY Terminal Switch position OFF If continuity is not as specified, replace the switch. A/C CONTROL CABLES ADJUSTMENT 1. ADJUST AIR INLET DAMPER CONTROL CABLE Set the air inlet damper and the control lever to ” FRESH” position, install the control cable and lock the clamp. 2. ADJUST AIR MIX DAMPER CONTROL CABLE Set the air mix damper and control switch to ”COOL” position, install the control cable and lock the clamp while lightly pushing the outer cable in the direction shown by the arrow. A/C CONTROL ASSEMBLY INSTALLATION (See page BO–108) AC–73 AIR CONDITIONING SYSTEM – SERVICE SPECIFICATIONS SERVICE DATA Refrigerant charge volume Drive belt tention New belt 5S–FE: Used belt New belt 1 MZ– FE: Used belt Idle speed 5S–FE: Magnetic clutch no engaged Magnetic clutch engaged 1 MZ– FE: Magnetic clutch noT engaged Magnetic clutch engaged Magnetic clutch clearance TORQUE SPECIFICATIONS Part tightened Suction hose x Compressor Discharge hose x Compressor Compressor x Engine Liquid x Receiver Lequid x Condensor Expansion valve x Evaporator Suction tube x A/C unit Liquid tube x A/C unit Pressure switch x Liquired tube SERVICE SPECIFICATIONS AX1–1 AUTOMATIC TRANSAXLE – A140E AUTOMATIC TRANSAXLE AX1–2 AUTOMATIC TRANSAXLE – DESCRIPTION DESCRIPTION PRECAUTIONS When working with FIPG material, you must observe the following. • Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces. • Thoroughly clean all components to remove all the loose material. • Clean both sealing surfaces with a non–residue solvent. • Apply the FIPG in approx.1 mm (0.04 in.) wide bead along the sealing surface. • Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied. If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. GENERAL DESCRIPTION The A140E Electronically Controlled automatic transaxle described in this AX section is a lock– up four–speed automatic transaxle developed exclusively for use with transversely–mounted engines. AX1–3 AUTOMATIC TRANSAXLE – SPECIFICATIONS Type of Transaxle Type of Engine Torque Converter Clutch Stall Torque Ratio Torque Converter Clutch Lock–up Mechanism Gear Ratio Transaxle 2nd Coast Brake (B,) Band Width 1 st Gear 2nd Gear 3rd Gear 0/D Gear Reverse Gear Number of Discs / Plates O/D Direct Clutch (Co) Forward Clutch (C,) Direct Clutch (Ct) 2nd Brake (Bz) 1 st & Reverse Brake (B,) O/D Brake (Bo) mm (in.) ATF Type Capacity liter (US qts, Imp.qts) Total Drain & Refill DESCRIPTION AX1–4 AUTOMATIC TRANSAXLE – OPERATION OPERATION 0 . . . . . Operating Shift lever position Gear Position Parking Reverse Neutral 2nd 3rd O/D 2nd ” 3rd *2nd ’ Down–shift only–no up–shift AX1–5 AUTOMATIC TRANSAXLE – OPERATION 1. FUNCTION OF COMPONENTS COMPONENT FUNCTION O/D Direct Clutch (Co) Connects Overdrive sun gear and overdrive carrier. 0/D Brake (Bo) Prevents overdrive sun gear from turning either clockwise or counterclockwise. O/D One–Clutch (Fo) When transaxle is being driven by engine, connects overdrive sun gear and overdrive carrier. Front Clutch (C1) Connects input shaft and intermediate shaft. Rear Clutch (C2) Connects input shaft and front & rear planetary gear. No. 1 Brake (B1) Prevents front & rear planetary sun gear from turning either clockwise or counterclockwise. No. 2 Brake (B2) Prevents outer race of F, from turning either clockwise or counterclockwise, thus preventing front & rear planetary sun gear from turning counterclockwise. No. 3 Brake (B3) Prevents front planetary carrier from turning either clockwise or counterclockwise. No. 1 One–Way Clutch (F1) When B2 is operating, prevents front & rear planetary sun gear from turning counterclockwise. No. 2 One–Way Clutch (F2) Prevents front planetary carrier from turning counterclockwise. AX1–6 AUTOMATIC TRANSAXLE – OPERATION Power from the engine transmitted to the input shaft via the torque converter clutch is then transmitted to the planetary gears by the operation of the clutch. By operation of the brake and one–way clutch, either the planetary carrier or the planetary sun gear are immobilized, altering the speed of revolution of the planetary gear unit. Shift change is carried out by altering the combination of clutch and brake operation. Each clutch and brake operates by hydraulic pressure. Gear position are decided according to the throttle opening angle and vehicle speed, and shift change automatically occurs. The conditions of operation for each gear position are shown on the following illustrations: AX1–7 AUTOMATIC TRANSAXLE – OPERATION 2. Hydraulic Control System The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves, the accumulator, the clutches and brakes, and the governor valve as well as the fluid passages which connect all of these components. Based on the hydraulic pressure created by the oil pump, the hydraulic control system governs the hydraulic pressure acting on the torque converter clutch, clutches and brakes in accordance with the vehicle driving conditions. There are three solenoid valves on the valve body. The shift solenoid valves No. 1 and No.2 are turned on and off by signals from the ECM to operate the shift valves and change the gear shift position. The No.3 solenoid valve is operated by signals from the ECM to engage or disengage the lock– up clutch of the torque converter clutch. AX1–8 AUTOMATIC TRANSAXLE – OPERATION 3. Electronic Control System The electronic control system for controlling the shift timing and the operation of the lock–up clutch is composed of the following three parts: (a) Sensors: These sense the vehicle speed and throttle position and send this data to the ECM in the form of electronic signals. (b) ECM: This determines the shift and lock–up timing based upon the signals from the sensors. (c) Actuators: Solenoid valves divert hydraulic pressure from one circuit of the hydraulic control unit to another, thus controlling shifting and lock–up timing. SENSORS ECM PATTERN SELECT SWITCH Control of shift timing PARK/NEUTRAL POSITION SWITCH ACTUATORS SHIFT SOLENOID i VALVE NO.1 SHIFT SOLENOID I VALVE NO.2 THROTTLE POSITION SENSOR VEHICLE SPEED SENSOR Control of lock– up timing SHIFT SOLENOID VALVE SL BRAKE LIGHT SWITCH O/D MAIN SWITCH Self–diagnostic system CRUISE CONTROL ECU ENGINE COOLANT TEMPERATURE SENSOR RPM SENSOR Back–up system O/D OFF INDICATOR LIGHT AX1–9 AUTOMATIC TRANSAXLE SYSTEM DIAGRAM – OPERATION AX1–10 AUTOMATIC TRANSAXLE – OPERATION ARRANGEMENT OF COMPONENTS Functions Components No. O/D OFF Indicator Light Blinks and warns the driver, while the 0/D main switch is pushed in, when the electronic control circuit is malfunctioning. Pattern Select Switch Selects the Power mode or the Normal mode for shift and lock–up timing. 0/D Switch Prevents up shift to the O/D gear if the O/D switch is off. Throttle Position Sensor Detects the throttle valve opening angle. ECM Controls the engine and transaxle,actuators based on signals from each sensor. Engine Coolant Temp. Sensor Detects the engine coolant temperature. Vehicle Speed Sensor Detect the vehicle speed. Ordinarily, transaxle control uses signals from the vehicle speed sensor. Park/Neutral Position Switch Detects the shift lever position. Shift Solenoid Valves No.1 and No.2 Control the hydraulic pressure applied to each shift valve, and control the gear shift position and timing. Shift Solenoid Valves SL For lock–up control pressure modulation Controls the hydraulic pressure applied to the lock–up clutch and controls lock–up timing. Stop Light Switch Detects if the brake pedal is depressed. AX1–11 AUTOMATIC TRANSAXLE – PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) 09043–38100 Hexagon 10 mm Wrench Remove and install oil pan drain plug. 09308–00010 Oil Seal Puller Remove side gear shaft oil seal. 09350–32014 TOYOTA Automatic Transmission Tool Set (09351–32010) One–way Clutch Test Toot (09351–32020) Stator Stopper (09351–32130) Handle (09351–32150) Oil Seal Replacer 09843–18020 Diagnosis Check Wire 09992–00094 Automatic Transmission Oil Pressure Gauge Set RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set Line pressure AX1–12 AUTOMATIC TRANSAXLE – PREPARATION EQUIPMENT Straight edge Check torque converter clutch installation. Vernier calipers Check torque converter clutch installation. Dial indicator or dial indicator with magnetic base Measures drive plate runout. Torque wrench LUBRICANT Item Automatic transaxle fluid (w/o Differential oil) Dry fill Drain and refill Differential oil (w/ Automatic transaxle) Capacity 5.6 liters (5.9 US qts, 4.9 Imp.qts) 2.5 liters (2.6 US qts, 2.2 Imp.qts) 1.6 liters (1.7 US qts, 1.4 Imp. qts) Classification ATF DEXRON 
ATF DEXRON 
SSM (SPECIAL SERVICE MATERIALS) 08833–00070 Adhesive 1311, THREE BOND 1311 or equivalent Torque converter clutch mounting bolt AX1–13 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR ON–VEHICLE REPAIR VALVE BODY REMOVAL 1. CLEAN TRANSAXLE EXTERIOR To help prevent contamination, clean the exterior of the transaxle. 2. DRAIN TRANSAXLE FLUID Remove the drain plug with SST, and drain the fluid into a suitable container. SST 09043–38100 3. REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the oil pan. Remove all pan bolts, and carefully remove the pan assembly discarding the gasket. 4. EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the pan and on the magnet to anticipate what type of wear you will find in the transaxle. Steel (magnetic): bearing, gear and plate wear Brass (non–magnetic): bushing wear 5. REMOVE OIL STRAINER AND APPLY TUBE BRACKET (a) Remove the 3 bolts and the oil strainer. NOTICE: Be careful as oil will come out of the strainer when it is removed. (b) Remove the 2 bolts and the apply tube bracket. 6. DISCONNECT SOLENOID CONNECTORS AX1–14 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR 7. REMOVE OIL TUBES Pry up the both tube ends with a large screwdriver and remove the four tubes. 8. REMOVE MANUAL DETENT SPRING 9. REMOVE MANUAL VALVE AND MANUAL VALVE BODY 10. REMOVE VALVE BODY Remove the 12 bolts. 11. REMOVE THROTTLE CABLE (a) Disconnect the throttle cable. (b) Remove the valve body. 12. REMOVE SECOND BRAKE APPLY GASKET AX1–15 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR VALVE BODY INSTALLATION 1. INSTALL SECOND BRAKE APPLY GASKET 2. INSTALL VALVE BODY (a) While holding the cam down with your hand, slip the cable and into the slot. (b) Bring valve body into place. NOTICE: Be careful not to entangle the solenoid wire. 3. INSTALL BOLTS IN VALVE BODY Hand tighten the 12 bolts first, then torque with a torque wrench. Torque: 10 N–m (100 kgf–cm, 7 ft–lbf) Bolt length: A 20 mm (0.79 in.) B 25 mm (0.98 in.) C 36 mm (1.42 in.) D50mm(1.97in.) 4. CONNECT SOLENOID WIRING (a) Connect the shift solenoid valve No. 1 connector (white and shorter wire). (b) Connect the shift solenoid valve No. 2 connector (black and longer wire). 5. INSTALL MANUAL VALVE BODY DETENT SPRING (a) Align the manual valve with the pin on the manual shaft lever. (b) Lower the manual valve body into place. (c) Hand tighten the 4 bolts first. Then, tighten them with a torque wrench. Torque: 10 N–m (100 kgf–cm, 7 ft–lbf) AX1–16 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR (d) Place the detent spring on the manual valve body and hand tighten the 2 bolts first. Then, tighten them with a torque wrench. Torque: 10 N–m (100 kgf–cm, 7 ft–lbf) (e) Check that the manual valve lever is touching the center of the detent spring tip roller. 6. INSTALL OIL TUBES Tap the tubes with a plastic hammer to install them into the positions indicated in the illustration. NOTICE: Be careful not to bend or damage the tubes. 7. INSTALL OIL STRAINER AND APPLY TUBE BRACK– ET (a) Install the oil strainer and torque the 3 bolts. (b) Install the apply tube bracket and the 2 bolts. Torque: 10 N–m (100 kgf–cm, 7s. ft–lbf) 8. INSTALL MAGNETS IN PAN Install the 2 magnets in the indentations of the pan. 9. INSTALL OIL PAN WITH NEW GASKET NOTICE: Make sure that the magnet does not interfere with the oil tubes. Torque: 4.9 N–m (50 kgf–cm, 43 in.–Ibf) 10. INSTALL DRAIN PLUG WITH NEW GASKET Using SST, install the drain plug with a new gasket and tighten it. Torque: 49 N–m (500 kgf–cm, 36 ft–lbf) SST 09043–38100 AX1–17 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR 11. FILL TRANSAXLE WITH ATF Add only about 2 liters of ATF. NOTICE: Do not overfill. Fluid type: ATF DEXRON
II 12. CHECK FLUID LEVEL (See page AX1–54) THROTTLE CABLE REMOVAL 1. DISCONNECT THROTTLE CABLE (a) Disconnect the cable housing from the bracket. (b) Disconnect the cable from the throttle linkage. 2. REMOVE PARK/NEUTRAL POSITION SWITCH (a) Remove the clips and, disconnect the transaxle con– trol cable from manual shift lever. (b) Remove the manual shift lever. (c) Remove the park/neutral position switch. 3. REMOVE VALVE BODY (See page AX–13) 4. PULL THROTTLE CABLE OUT OF TRANSAXLE CASE (a) Remove the bolt and retaining plate. (b) Pull the cable out of the transaxle case. AX1–18 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR THROTTLE CABLE INSTALLATION 1. INSTALL CABLE IN TRANSAXLE CASE (a) Be sure to push it in all the way. (b) Install the retaining plate and the bolt. 2. INSTALL VALVE BODY (See page AX–15) 3. IF THROTTLE CABLE IS NEW, STAKE STOPPER ON INNER CABLE (a) Bend the cable so there is a radius of about 200 mm (7.87 in.). (b) Pull the inner cable lightly until a slight resistance is felt, and hold it. (c) Stake the stopper 0.8–1.5 mm (0.031–0.059 in.) from the end of outer cable, as shown. 4. CONNECT THROTTLE CABLE (a) Connect the cable to the throttle linkage. (b) Connect the cable housing to the bracket. 5. ADJUST THROTTLE CABLE (See page AX1–55) 6. INSTALL PARK/NEUTRAL POSITION SWITCH (a) Install the park/neutral position switch. (b) Install the manual shift lever. (c) Adjust the park/neutral position switch. (See page AX1–56) (d) Connect the transaxle control cable. AX1–19 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR DIFFERENTIAL OIL SEAL REMOVAL 1. REMOVE BOTH DRIVE SHAFTS (See page SA–38) 2. REMOVE BOTH SIDE GEAR SHAFT OIL SEALS Using SST, pull out the oil seal. SST 09308–00010 DIFFERENTIAL OIL SEAL INSTALLATION 1. INSTALL LEFT SIDE GEAR SHAFT OIL SEAL (1) Using SST, drive in a new oil seal. SST 09350–32014 (09351–32130, 08351–32150) Oil seal depth: 2.7 ±0.5 mm (0.11 ±0.02 in.) (2) Coat the lip of oil seal with MP grease. 2. INSTALL RIGHT SIDE GEAR SHAFT OIL SEAL (1) Using SST, drive in a new oil seal. SST 09350–32014 (09351–32130, 09351–32150) Oil seal depth: 0 ± 0.5 mm (0
0.02 in.) (2) Coat the lip of seal with MP grease. 3. INSTALL BOTH DRIVE SHAFTS (See page SA–40) 4. CHECK TRANSAXLE FLUID LEVEL (See page AX1–54) AX1–20 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION ASSEMBLY REMOVAL AND INSTALLATION ASSEMBLY COMPONENTS AX1–21 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION TRANSAXLE REMOVAL CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY 2. REMOVE AIR CLEANER ASSEMBLY 3. REMOVE THROTTLE CABLE FROM ENGINE w/ Cruise Control System: 4. REMOVE CRUISE CONTROL ACTUATOR COVER 5. DISCONNECT CONNECTOR FROM CRUISE CON– TROL ACTUATOR 6. REMOVE GROUND TERMINAL 7. DISCONNECT CONNECTOR FROM VEHICLE SPEED SENSOR AX1–22 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 8. REMOVE STARTER (a) Disconnect the connector and nut. (b) Remove the 2 bolts and the starter. 9. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 10. DISCONNECT SOLENOID CONNECTOR 11. DISCONNECT OIL COOLER HOSE 12. DISCONNECT SHIFT CONTROL CABLE (a) Remove the clip from the control cable. (b) Remove the nut. AX1–23 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 13. REMOVE 2 FRONT SIDE ENGINE MOUNTING BOLT 14. REMOVE 2 BOLT AND CLAMP FROM FRONT FRAME ASSEMBLY 15. REMOVE 3 UPPER TRANSAXLE TO ENGINE BOLT 16. INSTALL ENGINE SUPPORT FIXTURE 17. TIE STEERING GEAR HOUSING TO ENGINE SUP – PORT FIXTURE BY CORD OR EQUIVALENT 18. RAISE AND SUITABLE SUPPORT VEHICLE 19. REMOVE FRONT WHEEL 20. REMOVE EXHAUST PIPE (a) Remove the 3 nuts. AX1–24 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION (b) Remove the 2 bolts and nuts from rear exhaust pipe. 21. REMOVE DIFFERENTIAL FLUID DRAIN PLUG AND GASKET 22. DRAIN DIFFERENTIAL FLUID INTO A SUITABLE CONTAINER 23. REMOVE RIGHT AND LEFT ENGINE SIDE COVER NO.2 24. REMOVE ENGINE UNDER FRONT COVER NO.1 AND NO.2 25. REMOVE DRIVE SHAFT (See page SA–38) 26. REMOVE FRONT SIDE ENGINE MOUNTING NUT 27. REMOVE 3 REAR SIDE ENGINE MOUNTING NUTS AX1–25 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 28. REMOVE ENGINE 4 TRANSAXLE MOUNTING BOLTS 29. REMOVE STEERING GEAR HOUSING (a) Remove the 4 bolts and disconnect stabilizer bar bus– hing bracket from the front frame assembly. (b) Remove the 2 bolts and nuts from the steering gear housing. (c) Remove the steering gear housing. 30. REMOVE FRONT FRAME ASSEMBLY (a) Hold the front frame assembly with a jack. (b) Remove the 2 set screws from the right and left fender liners. (c) Remove the 6 bolts and 4 nuts. (d) Remove the front frame assembly. AX1–26 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 31. REMOVE STIFFENER PLATE (a) Hold the transaxle with a jack. (b) Remove the 3 bolts and stiffener plate. 32. REMOVE REAR END PLATE (a) Remove the 4 bolts. (b) Remove the rear end plate. 33. REMOVE TORQUE CONVERTER CLUTCH MOUNT – ING BOLT (a) Turn the crankshaft to gain access to each bolt. (b) Hold the crankshaft pulley nut with a wrench and remove 6 bolts. HINT: First remove dark green colored bolt and then remove the others. 34. REMOVE 3 TRANSAXLE TO ENGINE BOLTS AX1–27 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 35. REMOVE TRANSAXLE ASSEMBLY Separate transaxle and engine, and lower the trans– axle. 36. REMOVE TORQUE CONVERTER CLUTCH FROM TRANSAXLE TRANSAXLE INSTALLATION 1. INSTALL TORQUE CONVERTER CLUTCH IN TRA– NSAXLE If the torque converter clutch has been drained and washed, refill with new ATF. Fluid Type: ATF DEXRON

2. CHECK TORQUE CONVERTER CLUTCH INSTALLA– TION Using a scale and a straight edge, measure from the installed surface to the front surface of the transaxle housing. Correct distance: 13.0 mm (0.51 in.) or more 3. ALIGN TRANSAXLE AT INSTALLATION POSITION (a) Align the 2 knock pins on the block with the converter housing. (b) Temporarily install the bolt. 4. INSTALL TRANSAXLE TO ENGINE BOLT Install the transaxle to engine bolts. 12 mm head bolt Torque: 64 N–m (650 kgf–cm, 47 ft–lbf) AX1–28 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 10 mm head bolt Torque: 46 N–m (470 kgf–cm, 34 ft–lbf) 5. INSTALL TORQUE CONVERTER CLUTCH MOUNT– ING BOLT (a) Clean the threads of the bolts with the gasoline. (b) Coat the threads of the bolts with sealer. Sealer: Part No.08833–00070, THREE BOND 1324 or equi– valent. (c) Tighten the bolts evenly. Torque: 27 N–m (280 kgf–cm, 20 ft–Ibf) HINT: First install dark green colored bolt and then the 5 bolts. 6. INSTALL REAR END PLATE Install the rear end plate with the 4 bolts. 7. INSTALL STIFFENER PLATE (a) Install the stiffener plate with the 3 bolts. (b) Torque the 3 bolts. Torque: 37 N–m (380 kgf–cm, 27 ft–lbf) 8. INSTALL FRONT FRAME ASSEMBLY (a) Hold the front frame assembly with a jack. (b) Install the front frame assembly with the 6 bolts and 4 nuts. (c) Torque the bolts. 19 mm head bolt Torque: 181 N–m (1,850 kgf–cm, 134 ft–lbf) 12 mm head bolt Torque: 32 N–m (330 kgf–cm, 24 ft–lbf) AX1–29 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION (d) Torque the nuts. Nut Torque: 36 N–m (370 kgf–cm. 27 ft–lbf) (c) Install the 2 set screws in the right and left fender liners. 9. INSTALL STEERING GEAR HOUSING (a) Install the steering gear housing to the front frame assembly. (b) Install and torque the 2 bolts and nuts. Torque: 181 N–m (1,850 kgf–cm, 134 ft–lbf) (c) Connect the stabilizer bar bushing bracket with the 4 bolts. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) 10. INSTALL 4 TRANSAXLE MOUNTING BOLTS Torque: 52 N–m (530 kgf–cm, 38 ft–lbf) AX1–30 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 11. INSTALL 3 REAR SIDE ENGINE MOUNTING NUTS Torque: 66 N–m (670 kgf–cm, 48 ft–Ibf) 12. INSTALL FRONT SIDE ENGINE MOUNTING NUT Torque: 80 N–m (820 kgf–cm, 59 ft–lbf) 13. INSTALL DRIVE SHAFT (See page SA–40) 14. INSTALL RIGHT AND LEFT ENGINE SIDE COVER N O.2 15. INSTALL ENGINE UNDER FRONT COVER NO.1 AND NO.2 16. INSTALL DIFFERENTIAL FLUID DRAIN PLUG WITH A NEW GASKET 17. FILL DIFFERENTIAL FLUID Fluid Type: ATF DEXRON
ll Capacity: Differential 1.6 liters (1.7 US qts, 1.4 Imp. qts) 18. CHECK DIFFERENTIAL FLUID LEVEL 19. INSTALL EXHAUST PIPE (a) Install and torque the 3 nuts. Torque: 62 N–m (630 kgf–cm, 46 ft–lbf) AX1–31 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION (b) Install the rear exhaust pipe with the 2 bolts and nuts. Torque: 103 N–m (1,050 kgf–cm, 76 ft–lbf) 20. INSTALL FRONT WHEEL AND LOWER VEHICLE Torque: 103 N–m (1,050 kgf–cm, 76 ft–lbf) 21. UNTIE STEERING GEAR HOUSING TO ENGINE SUP – PORT FIXTURE BY CORD OR EQUIVALENT 22. REMOVE ENGINE SUPPORT FIXTURE 23. INSTALL 3 UPPER TRANSAXLE TO ENGINE BOLTS Torque: 64 N–m (650 kgf–cm. 47 ft–lbf) 24. INSTALL 2 BOLTS AND CLAMP FROM TO FRAME ASSEMBLY 25. INSTALL 2 FRONT SIDE ENGINE MOUNTING BOLTS Torque: 80 N–m l820 kgf–cm, 59 ft–lbfj AX1–32 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 26. CONNECT SHIFT CONTROL CABLE (a) Install the clip to the control cable. (b) Install the nut. (c) Adjust the control cable. (See page AX1–55) 27. CONNECT OIL COOLER HOSE 28. CONNECT SOLENOID CONNECTOR 29. CONNECT PARK/ NEUTRAL POSITION SWITCH CONNECTOR 30. INSTALL STARTER (a) Install the starter with 2 bolts. Torque: 39 N–m (400 kgf–cm, 29 ft–lbf) (b) Connect the connector and nut. AX1–33 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 31. CONNECT VEHICLE SPEED SENSOR CONNECTOR 32. INSTALL GROUND TERMINAL w/ Cruise Control System: 33. CONNECT CONNECTOR TO CRUISE CONTROL ACTUATOR 34. INSTALL CRUISE CONTROL ACTUATOR COVER 35. INSTALL THROTTLE CABLE TO ENGINE (a) Torque the nuts. Torque: 15 N–m (150 kgf–cm, 11 ft–lbf) (b) Adjust the throttle cable. (See page AX1–55) 36. INSTALL AIR CLEANER ASSEMBLY 37. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY AX1–34 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 38. FILL TRANSAXLE WITH ATF Fluid type: ATF DEXRON  II Capacity: 5.6 liters (5.9 US gts, 4.9 Imp.gts) 39. CHECK FLUID LEVEL (See page AX1–64) 40. INSPECT FRONT WHEEL ALIGNMENT (See page SA–40) 41. PERFORM ROAD TEST Check for abnormal noise and smooth shifting. TORQUE CONVERTER CLEANING If the transaxle is contaminated, the torque converter and transmission cooler should be thoroughly flushed with ATF. TORQUE CONVERTER CLUTCH AND DRIVE PLATE INSPECTION 1. INSPECT ONE–WAY CLUTCH (a) Install SST into the inner race of the one–way clutch. SST 09350–33014 (09351–32010) AX1–35 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION (b) Install SST so that it fits in the notch of the converter hub and outer race of the one–way clutch. SST 09350–32014 (09351–32020) (c) With the torque converter clutch standing on its side, the clutch locks when turned counterclockwise, and rotates freely and smoothly clockwise. If necessary, clean the converter clutch and retest the clutch. Replace the converter clutch if the clutch still fails the test. 2. MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR Set up a dial indicator and measure the drive plate runout. If runout exceeds 0.20 mm (0.0079 in.) or if the ring gear is damaged, replace the drive plate. If installing a new drive plate, note the orientation of spacers and tighten the bolts. Torque: 83 N–m (850 kgf–cm, 61 ft–lbf) 3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT (a) Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator. If runout exceeds 0.30 mm (0.0118 in.), try to correct by reorienting the installation of the converter. If ex– cessive runout cannot be corrected, replace the torque converter clutch . HINT: Mark the position of the converter clutch to ensure correct installation. (b) Remove the torque converter clutch. AX1–36 AUTOMATIC TRANSAXLE SHIFT LOCK SYSTEM COMPONENT PARTS LOCATION WIRING DIAGRAM – SHIFT LOCK SYSTEM AX1–37 AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM ELECTRIC CONTROL COMPONENTS INSPECTION 1. INSPECT SHIFT LOCK CONTROL ECU Using a voltmeter, measure the voltage at each termi– nals. HINT: Do not disconnect the ECU connector. Connector Terminal Measuring condition Voltage (V) Ignition switch ACC position Ignition switch ON position Depress brake pedal Ignition switch ACC position and P position Ignition switch ACC position and except P position (Approx–after 1 second) Ignition switch ON position and P position Depress brake pedal (Approx–after 20 seconds) Except P position Ignition switch ON, P position and depress brake pedal Shift except P position under conditions above Ignition switch ACC position and P position Shift except P position under condition above 2. INSPECT SHIFT LOCK SOLENOID (a) Disconnect the solenoid connector. (b) Using an ohmmeter, measure the resistance between terminals. Standard resistance: 21–27
(c) Apply the battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid. AX1–38 AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM 3. INSPECT KEY INTERLOCK SOLENOID (a) Disconnect the solenoid connector. (b) Using an ohmmeter, measure the resistance between terminals. Standard resistance: 12.5–16.50 (c) Apply the battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid. 4. INSPECT SHIFT LOCK CONTROL SWITCH Inspect that there is continuity between each termi– nal. Terminal Shift Position P position (Release button is not pushed) P position (Release button is pushed) R, N, D, 2, L Position AUTOMATIC TRANSAXLE – TROUBLESHOOTING TROUBLESHOOTING AX1–40 AUTOMATIC TRANSAXLE – TROUBLESHOOTING HOW TO PROCEED WITH TROUBLESHOOTING For troubleshooting using a volt/ohm meter, see page AX1–40
42. HOW TO PROCEED WITH TROUBLESHOOTING USING VOLT OHM METER 1. CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in as much detail as possible about the problem. 2. CHECK AND CLEAR THE DIAGNOSTIC TROUBLE CODES (PRECHECK) Before confirming the problem symptom, first check the diagnostic trouble code if there are any trouble codes stored in memory. When there are trouble codes, make a note of them, then clear them and proceed to “3. Problem Symptom Confirmation”. 3. PROBLEM SYMPTOM CONFIRMATION Confirm the problem symptoms. 4. SYMPTOM SIMULATION If the problem does not reappear, be sure to simulate the problem by mainly checking the circuits indicated by the diagnostic trouble code in step 2, using “Problem Simulation method”. 5. DIAGNOSTIC TROUBLE CODE CHECK Check the diagnostic trouble codes. Check if there is abnormality in the sensors or the wire harness. If a trouble code is output, proceed to “6. Diagnostic Trouble Code Chart”. If the normal code is output, proceed to “7. Matrix Chart of Problem Symptoms”. Be sure to proceed to “6. Diagnostic Trouble Code Chart” after steps 2 and 3 are completed. If troubleshooting is attempted only by following the trouble code stored in the memory is output, errors could be made in the diagnosis. 6. DIAGNOSTIC TROUBLE CODE CHART If a trouble code is confirmed in the diagnostic trouble code check, proceed to the inspection procedure indicated by the matrix chart for each diagnostic trouble code. 7. PRELIMINARY CHECK Carry out a preliminary check of the transaxle oil level, throttle cable adjustment, etc. 8. SHIFT POSITION SIGNAL CHECK Carry out the shift position signal check when the transaxle gears do not up–shift, down–shift or lock–up. This is to check the signal output condition from the ECM to each solenoid. If the results are NG, then it is likely that the trouble is in the electrical system (particularly in the sensors or the ECM). Proceed to Part 1 (Electrical System) under “ 11. Matrix Chart of Problem Symptoms”. If all the circuits specified in Part 1 are OK, check the ECM and replace it. 9. MECHANICAL SYSTEM TEST (Stall Test, Time Leg Test, Line Pressure Test) If the malfunction is found in the stall test, time lag test or line pressure test, check the parts indicated in the respective tests. 14. MANUAL SHIFTING TEST If the results of the manual driving test are NG, it is likely that the trouble is in the mechanical system or hydraulic system. Proceed to Part 2 (Mechanical System) under the Matrix Chart of Problem Symptoms. AX1–41 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 11. MATRIX CHART OF PROBLEM SYMPTOMS If the normal code is confirmed in the diagnostic trouble code check, perform inspection according to the inspection order in the matrix chart of problem symptoms. Perform diagnosis of each circuit or part in the order shown in the Matrix Chart. The Matrix Chart contains 3 chapters, Electronically Controlled Circuits in Chapter 1, On–vehicle Inspection in Chapter 2 and Off– vehicle Inspection in Chapter 3. If all the circuits indicated in Chapter 1 are normal, proceed to Chapter 2. If all the parts indicated in Chapter 2 are normal, proceed to Chapter 3. If all the circuits and parts in Chapter 1–Chapter 3 are normal and the trouble still occurs, check and replace the ECM. 12. CIRCUIT INSPECTION Perform diagnosis of each circuit in accordance with the inspection order confirmed in steps 6 and 11. Judge whether the cause of the problem is in the sensor, actuators, wire harness and connectors, or the ECM. In some cases, the Flow Chart instructs that a throttle signal check, brake signal check or kick–down signal check (in test mode), be performed. These are diagnosis functions used to check if signals are being input correctly to the ECM. 13. PART INSPECTION Check the individual parts of the mechanical system and hydraulic system in the order of the numbers indicated in the Matrix Chart. 14. REPAIRS After the cause of the problem is located, perform repairs by following the inspection and replacement procedures in this manual or’94 Al 40E AUTOMATIC TRANSAXLE Repair Manual. 15. CONFIRMATION TEST After completing repairs, confirm not only that the malfunction is eliminated, but also conduct a test drive, etc., to make sure the entire electronically controlled transaxle system is operating correctly. AX1–42 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Items inside are titles of pages, in this man– ual, with the page number indicated in the bot– tom portion. See the indicated pages for detailed Customer Problem Analysis explanations. P. AX1–43 Step 2, 5, 12, 15: Diagnostic steps permitting the use of the TOYOTA Check and Clear Diagnostic Trouble. Codes (Precheck) hand–held tester or TOYOTA Precheck) brake–out–box. P. AX1–44–AX1–46 Vehicle Brought to Workshop 1. Symptom does not occur 4. Problem Symptom Confirmation Symptom Simulation P. IN–24 P. AX1–48 Symptom occurs OK Code Preliminary Check Diagnostic Trouble Code Check P.AX–44
AX1–45 NG P. AX1–54 Shift Position Signal Check Diagnostic Trouble Code Chart P. AX1–47 P. AX1–64– OK Mechanical System Tests P. AX1–57 OK 10. Manual Shifting Test P. AX1–63 Matrix Chart of Problem Symptoms– P. AX1–67 Chapter 1 (Electronic) P. AX1–68 12. Circuit Inspection Chapter 2 (On–Vehicle) P. AX1–70 Chapter 3 (OFF–Vehicle) P. AX1–72 13. • Main Throttle Signal Check • Stop Light Signal Check Parts Inspection P.AX1–80
AX1–112 15. Identification of Problem Repair Confirmation Test END AX1–43 AUTOMATIC TRANSAXLE – TROUBLESHOOTING CUSTOMER PROBLEM ANALYSIS AX1–44 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSIS SYSTEM The Electronically Controlled Transaxle has built–in self–diagnostic functions. If the malfunction occurs in the system, the ECM stores the diagnostic trouble code in memory and the O/D OFF (Overdrive OFF) indicator light blinks to inform the driver. The diagnos– tic trouble code stored in memory can be read out by the following procedure. O/D OFF INDICATOR LIGHT INSPECTION 1. Turn the ignition switch to ON. 2. Check if the O/D OFF indicator light lights up when the O/D main switch is pushed out to OFF and goes off when the O/D main switch is pushed in to ON. HINT: • If the O/D OFF indicator light does not light up or stay on all the time, carry out the check for ’O/D OFF Indicator Light Circuit” on page AX–102. • If the O/D OFF indicator light blinks, a trouble code is stored in the ECM memory. DIAGNOSTIC TROUBLE CODE CHECK 1. Turn the ignition switch ON, but do not start the engine. 2. Push in the O/D main switch to ON. HINT: Warning and diagnostic trouble codes can be read only when the O/D main switch is ON. If it is OFF, the 0/D OFF indicator light up will light continu– ously and will not blink. 3. Using SST, connect terminals TE1 and El of the DLC1 or DLC2. SST 09843–18020 AX1–45 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 4: Read the diagnostic trouble code indicated by the number of times the O/D OFF indicator light blinks. HINT: If the system is operating normally, the light will blink 2 times per second. Diagnostic trouble code “42” is shown as an example. HINT: When 2 or more trouble codes are stored in memory, the lower–numbered code is displayed first. If no diagnostic trouble code is output, or if a diagnos– tic trouble code is output even though no diagnostic trouble code output operation is performed, check the TE1 terminal circuit on page AX1–110. DIAGNOSTIC TROUBLE CODE CHECK BY USING TOYOTA HAND–HELD TESTER 1. Hook up the TOYOTA hand–held tester to the DLC2. 2. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the TOYOTA hand–held tester operator’s manual for further details. CANCELLING DIAGNOSTIC TROUBLE CODE After repair of the trouble area, the diagnostic trouble code retained in the ECM memory must be cancelled out by removing the EM fuse for 10 seconds or more, with the ignition switch off. Check that the normal code is output after connecting the fuse. AX1–46 AUTOMATIC TRANSAXLE – TROUBLESHOOTING ECM TERMINALS STANDARD VALUE ECM TERMINAL VALUES MEASUREMENT BY USING TOYOTA BREAK–OUT–BOX AND TOYOTA HAND–HELD TESTER 1. Hook up the TOYOTA break–out–box and TOYOTA hand–held tester to the vehicle. 2. Read the ECM input/output values by following the prompts on the tester screen. HINT: TOYOTA hand–held tester has a “Snapshot” function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the TOYOTA hand–held tester / TOYOTA break–out–box operator’s manual for fur– ther details. AX1–47 AUTOMATIC TRANSAXLE – TROUBLESHOOTING CHECK TERMINAL TT OUTPUT VOLTAGE When a voltmeter is connected to the DLC2, the following items can be checked: 1. Throttle position sensor signal 2. Brake signal 3. Shift position signal 1. VOLTMETER CONNECTION Connect the positive (+) probe of the voltmeter to terminal Tt and the negative (–) probe to terminal E1 of the DLC2. HINT: If a voltmeter with small internal resistance is used, the correct voltage will not be indicated, so use a voltmeter with an internal resistance of at least 10 k
. 2. TURN IGNITION SWITCH TO ON (DO NOT START THE ENGINE) 3. CHECK THROTTLE POSITION SENSOR SIGNAL Check if the voltage changes from approximately 0 V to approximately 8 V when the accelerator pedal is gradually depressed from the fully closed position. 4. CHECK BRAKE SIGNAL (LOCK–UP CUT SIGNAL) (a) Open the throttle valve fully to apply approximately 8 V to terminal Tt. (b) In this condition, check terminal Tr voltage when the brake pedal is depressed and released. Tt terminal voltage: 0 V (When brake pedal is depressed) 8 V (When brake pedal is released) 5: START ENGINE 6. CHECK SHIFT POSITION SIGNAL (VEHICLE SPEED ABOVE 10 KM/H OR 6 MPH) Check up–shifting together with terminal TT voltage. HINT: Check for light shocks from up–shifting and for changes in the tachometer. Gear Position Terminal TT output voltage 1 st Gear Below 0.5 V 2nd Gear 1.5–2.6 V 2nd Lock–up 2.5–3.6 V 3rd Gear 3.5–4.6 V 3rd Lock–up 4.5–5.6 V O/D 5.5–6.6 V 0/D Lock–up 6.5–7.6 V If terminal TT output voltage check cannot be perfo– rmed, check TT terminal circuit on page AX1–112. AX1–48 AUTOMATIC TRANSAXLE – TROUBLESHOOTING PROBLEM SYMPTOM CONFIRMATION Taking into consideration the results of the customer problem analysis, try to reproduce the symptoms of the trouble. If the problem is that the transaxle does not up–shift, does not down –shift, or the shift point is too high or too low, conduct the following road test to confirm the automatic shift schedule and simulate the problem symptoms. ROAD TEST NOTICE: Perform the test at normal ATF operating tem– perature 50–80
C (122–176
F). 1. D POSITION TEST Shift into the D position and keep the accelerator pedal constant at the full throttle valve opening posi– tion, and check the following points: (a) Check up–shift operation. Check that 1–2, 2–3 and 3–O/D up–shift takes place, at the shift point shown in the automatic shift schedule. (See page AX1–52) HINT: (1) 0/D Gear Up–shift Prohibition Control. • Coolant temp. is 50
C (122
F) or less • If there is a 10 km/h (6 mph) difference between the set cruise control speed and vehicle speed. • 0/D main switch is pushed ON (During the O/D OFF indicator light lights up.) (2) 0/D Gear Lock–up Prohibition Control. • Brake pedal is depressed. • Coolant temp. is 50
C (122
F) or less. (b) Check for shift shock and slip. Check for shock and slip at the 1–2, 2–3 and 3–0/ D up–shifts. AX1–50 AUTOMATIC TRANSAXLE – TROUBLESHOOTING (c) Check for abnormal noise and vibration. Run at the D position lock–up or O/D gear and check for abnormal noise and vibration. HINT: The check for the cause of abnormal noise and vibration must be performed very thoroughly as it could also be due to loss of balance in the torque converter clutch, etc. (d) Check kick–down operation. While running in the D position, 2nd, 3rd and O/D gears, check to see that the possible kick–down vehicle speed limits for 2
1, 3
2 and O/D
3 kick–downs conform to those indicated on the auto– matic shift schedule. (See page AX1–52) (e) Check abnormal shock and slip at kick–down. (f) Check the lock–up mechanism. (1) Drive in D position, O/D gear, at a steady speed (lock–up ON) of about 75 km/h (47 mph). (2) Lightly depress the accelerator pedal and check that the RPM does not change abruptly. If there is a big jump in RPM, there is no lock–up. 2. 2 POSITION TEST Shift into the 2 position and, while driving with the accelerator pedal held constantly at the full throttle valve opening position and check on the following points: (a) Check up–shift operation Check to see that the 1
2 up–shift takes place and that the shift point conforms to the automatic shift schedule. (See page AX1–52) HINT: There is no O/D up–shift and lock–up in the 2 position. AX1–51 AUTOMATIC TRANSAXLE – TROUBLESHOOTING (b) Check engine braking. While running in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. (c) Check for abnormal noises during acceleration and deceleration, and for shock at up–shift and down– shift. 3. L POSITION TEST Shift into the L position and while driving with the accelerator pedal held constantly at the full throttle valve opening position, and check the following points: (a) Check no up–shift. While running in the L position, check that there is no up–shift to 2nd gear. (b) Check engine braking. While running in the L position, release the accelera– tor pedal and check the engine braking effect. (c) Check for abnormal noises during acceleration and deceleration. AX1–52 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 4. R POSITION TEST Shift into the R position and while starting at full throttle, check for slipping. CAUTION: Before conducting this rest ensure that the test area is free from personnel and obstructions. 5. P POSITION TEST Stop the vehicle on a gradient (more than 5
) and after shifting into the P position, release the parking brake. Then check to see that the parking lock pawl holds the vehicle in place. AX1–52 AUTOMATIC TRANSAXLE – TROUBLESHOOTING AUTOMATIC SHIFT SCHEDULE SHIFT POINT NORM Mode Shift position Shifting point Vehicle speed km/h (mph) Shifting point Vehicle speed km/h (mph) D position 2 position L position PWR Mode Shift position D position 2 position L position AX1–53 AUTOMATIC TRANSAXLE – TROUBLESHOOTING LOCK–UP POINT NORM Mode D position Throttle valve opening 596 Lock–up ON km/h (mph) Lock–up OFF km/h (mph) Lock–up ON km/h (mph) Lock–up OFF km/h (mph) 3rd Gear O/D Gear PWR Mode D position Throttle valve opening 596 3rd Gear O/D Gear *O/D main switch OFF HINT: (1) In the 2 and L positions, all stages lock–up is OFF. (2) In the following cases, the lock–up will be released regardless of the lock–up pattern. • When the throttle valve is completely closed. • When the brake light switch is ON. AX1–54 AUTOMATIC TRANSAXLE – TROUBLESHOOTING PRELIMINARY CHECK 1. CHECK FLUID LEVEL HINT: • Drive the vehicle so that the engine and transaxle are at normal operating temperature. Fluid temp.: 70–80 C (158–176 F) • Only use the COOL range on the dipstick as a rough reference when the fluid is replaced or the engine does not run. (a) Park the vehicle on a level surface and set the parking brake. (b) With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L position and return to P position. (c) Pull out the oil level gauge and wipe it clean. (d) Push it back fully into the tube. (e) Pull it out and check that–the fluid level is in the HOT range. If the level is at the low side, add fluid. Fluid type: ATF DEXRON
II NOTICE: Do not overfill. 2. CHECK FLUID CONDITION If the fluid smells burnt or is black, replace it. 3. REPLACE TRANSAXLE FLUID (a) Using SST, remove the drain plug and drain the fluid. SST 09043–38100 (b) Reinstall the drain plug securely. (c) With the engine OFF, add new fluid through the oil filler tube. Fluid type: ATF DEXRON^II Capacity: Total: 5.6 liters (5.9 US qts, 4.9 Imp. qts) Drain and refill: 2.5 liters (2.6 US qts. 2.2 Imp. qts) (d) Start the engine and shift the shift lever into all posi– tions from P to L position and then shift into P posi– tion. (e) With the engine idling, check the fluid level. Add fluid up to the COOL level on the dipstick. (f) Check the fluid level at the normal operating tempera– ture 70–80 C (158–176 F) and add as neces– sary. NOTICE: Do not overfill. 4. CHECK FLUID LEAKS Check for leaks in the transaxle. If there are leaks, it is necessary to repair or replace O –rings, seal packings, oil seals, plugs or other parts. AX1–55 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 5. INSPECT AND ADJUST THROTTLE CABLE (a) Check that the throttle valve is fully closed. (b) Check that the inner cable is not slack. (c) Measure the distance between the outer cable end and stopper on the cable. Standard distance: 0–1 mm (0–0.04 in.) If the distance is not standard, adjust the cable by the adjusting nuts. 6. INSPECT AND ADJUST SHIFT CABLE When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator correctly indicates the position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures: (a) Loosen the swivel nut on the manual shaft lever. (b) Push the manual shaft lever fully toward the right side of the vehicle. (c) Return the control shaft lever 2 notches to U position. (d) Set the shift lever to N position. (e) While holding the shift lever lightly toward the R position side, tighten the shift lever nut. AX1–56 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 7. INSPECT AND ADJUST PARK/NEUTRAL POSITION SWITCH Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as started above, carry out the following adjust– ment procedure: (a) Loosen the park/neutral position switch bolt and set the shift lever to the N position. (b) Align the groove and neutral basic line. (c) Hold in position and tighten the bolt. Torque: 5.4 N–m (55 kgf–cm, 48 in.¿lbf) 8. INSPECT IDLE SPEED (N POSITION) Idle speed: 750 rpm (In N position and air conditioner OFF) AX1–57 AUTOMATIC TRANSAXLE – TROUBLESHOOTING MECHANICAL SYSTEM TESTS STALL TEST The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D and R positions. NOTICE: • Perform the test at normal operating fluid temperature 50–80
C (122–176
F). • Do not continuously run this test longer than 5 seconds. • To ensure safety, conduct this test in a wide, clear, level area which provides good traction. • The stall test should always be carried out in pairs. One technician should observe the conditions of the wheels or wheel stoppers outside the vehicle while the other is performing the test. MEASURE STALL SPEED (a) Chock the 4 wheels. (b) Connect a tachometer to the engine. (c) Fully apply the parking brake. (d) Keep your left foot pressed firmly on the brake pedal. (e) Start the engine. (f) Shift into the D position. Fully depress the accelerator pedal with your right foot. Quickly read the stall speed. Stall speed: 2,450 ±150 rpm (g) Perform the same test in R position. Quickly read the stall speed. Stall speed: 2,450 ±150 rpm AX1–58 AUTOMATIC TRANSAXLE – TROUBLESHOOTING EVALUATION Possible cause Problem • Engine output may be insufficient. • Stator one–way clutch is operating properly (a) Stall speed low in D and R positions. (b) Stall speed high in D position. (c) Stall speed high in R position. (d) Stall speed high in D and R position. HINT: If more than 600 rpm below the specified value, the torque converter clutch could be faulty. • • • • Line pressure too low Forward clutch slipping No.2 one–way clutch not operating properly 4/D one–way clutch not operating properly • • • • Line pressure too low Direct clutch slipping First and reverse brake slipping O/D clutch slipping • Line pressure too low • Improper fluid level • 0/D one–way clutch not operating properly AX1–59 AUTOMATIC TRANSAXLE – TROUBLESHOOTING TIME LAG TEST When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the 4/D direct clutch, forward clutch, direct clutch, and first and reverse brake. NOTICE: • Perform the test at normal operating fluid temperature 50–80
C (122–176
F). • Be sure to allow a one minute Interval between tests. • Make 3 measurements and take the average value. • MEASURE TIME LAG (a) Fully apply the parking brake (b) Start the engine and check idle speed. Idle speed: 750 rpm (in N position and air conditioner OFF) (c) Shift the shift lever from N to D position. Using a stop watch, measure the time it takes from shifting the lever until the shock is felt. In same manner, measure the time lag for N–R. Time lag: N
D Less than 1.2 seconds N
R Less than 1 .5 seconds AX1–60 AUTOMATIC TRANSAXLE – TROUBLESHOOTING EVALUATION If N
D or N
R time lag are longer than specified: Possible cause Problem N
D time lag is longer • Line pressure too low • Forward clutch worn • O/D one–way clutch not operating properly N
R time lag is longer • • • • Line pressure too low Direct clutch worn First and reverse brake worn O/D clutch worn AX1–61 AUTOMATIC TRANSAXLE – TROUBLESHOOTING HYDRAULIC TEST MEASURE LINE PRESSURE NOTICE: • Perform the test at normal operating fluid temperature 50–80
C (122–176
F). • The line, pressure test should always be carried out in pairs. One technician should observe the conditions of the wheels or wheel stoppers outside the vehicle while the other is performing the test. (a) Warm up the transaxle fluid. (b) Remove the test plug on the transaxle case left side and connect the oil pressure gauge SST. SST 09992–00094 (c) Fully apply the parking brake and chock the 4 wheels. (d) Start the engine and check idling RPM. (e) Keep your left foot pressed firmly on the brake pedal and shift into D position. (f)’ Measure the line pressure when the engine is idling. (g) Fully depress the accelerator pedal. Quickly read the highest line pressure when engine speed reaches stall speed. (h) In the same manner, perform the test in R position. SPECIFIED LINE PRESSURE Line pressure Idling Stall D position kPa (kgf/emt, psi) R position kPa (kgf/cmt, psi) 362–422 (3.7–4.3, 53–61) 618–794 (6.3–8.1,90–115) 750–897 (7.7–9.2,109–130) 1,373–1,608 (14.0–16.4,199–233) If the measured pressures are not up to specified values, recheck the throttle cable adjustment and retest. AX1–62 AUTOMATIC TRANSAXLE – TROUBLESHOOTING EVALUATION Possible cause Problem If the measured values at all positions are higher. If the measured values at all positions are lower. If pressure is low in the D position only. If pressure is low in the R position only. • • • • • • • • • • • • • Throttle cable out of adjustment Throttle valve defective Regulator valve defective Throttle cable out of adjustment Throttle valve defective Regulator valve defective Oil pump defective O/D direct clutch defective D position circuit fluid leakage Forward clutch defective R position circuit fluid leakage Direct clutch defective First and reverse brake defective AX1–63 AUTOMATIC TRANSAXLE – TROUBLESHOOTING MANUAL SHIFTING TEST HINT: With this test, it can be determined whether the trouble is within the electrical circuit or is a mechani– cal problem in the transaxle. 1. DISCONNECT SOLENOID WIRE 2. INSPECT MANUAL DRIVING OPERATION Check that the shift and gear positions correspond with the table below. Shift Position Gear Position D Position O/D 2 Position 3rd L Position R Position Reverse P Position Pawl Lock HINT: If the L, 2 and D position gear positions are difficult to distinguish, perform the following road test. • While driving, shift through the L, 2 and D positions. Check that the gear change corresponds to the shift position. If any abnormality is found in the above test, the problem is in the transaxfe itself. 3. CONNECT SOLENOID WIRE 4. CANCEL OUT DIAGNOSTIC TROUBLE CODE (See page AX1–45) AUTOMATIC TRANSAXLE -Memo – TROUBLESHOOTING AUTOMATIC TRANSAXLE -Memo – TROUBLESHOOTING AX1–66 AUTOMATIC TRANSAXLE – TROUBLESHOOTING STANDARD VALUE OF ECM TERMINAL ECM Terminals Symbols Condition Wiring Color Standard Value IG OFF IG ON Vehicle driving in 2nd gear position IG OFF • G ON Vehicle driving in 2nd gear position IG OFF IG ON Vehicle driving under lock–up position IG ON IG ON IG ON • G ON lG ON Pattern select SW: PWR Pattern select SW: NORM Brake pedal is depressed Brake pedal is released Engine Coolant temp. 80
C (1 76T) Accel. pedal is released Accel. pedal is depressed Accel. pedal is released Accel. pedal is depressed tG ON IG ON OD main SW: ON OD main SW: OFF IG ON Disconnect following connectors: • Cruise control ECU P or N position IG ON P and N position IG ON 2 position Except 2 position lG ON L position Except L position Standing still Turn one front wheel slowly. AX1–67 AUTOMATIC TRANSAXLE – TROUBLESHOOTING MATRIX CHART OF PROBLEM SYMPTOMS If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. The Matrix Chart is divided into 3 chapters. Chapter 1: Electronic Circuit Matrix Chart Chapter 2: On–vehicle Repair Matrix Chart Chapter 3: Off–vehicle Repair Matrix Chart When troubleshooting, check Chapter 1 first. If instructions are given in Chapter 1 to proceed to Chapter 2 or 3, proceed as instructed. 1. If the instruction “Proceed to next circuit inspection shown on matrix chart” is given in the flow chart for each circuit, proceed to the circuit with the next highest number in the table to continue the check. 2. If the trouble still occurs even though there are no abnormalities in any of the other circuits, then check or replace the ECM. AX1–68 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Vehicle does not move in any forward position and reverse position Vehicle does not move in a particular position or positions 1 st ± 2nd No up–shift 2nd¿¿ 3rd 3rd
O/D 0 / D
3rd No down–shift 3rd
2nd 2nd
1 st No lock–up No lock–up off Shift point too high or *too low Up–shifts to 2nd while in L position Up–shifts to 3rd while in L position Up–shifts to O/D from 3rd while O/D switch is OFF Up–shifts to O/D from 3rd while engine is cold N
D Harsh engagement Lock–up Any driving position Forward and reverse Slip or Shudder Particular position No engine braking Poor acceleration No–kick–down No pattern select Large shift shock or engine stalls when starting off or stopping. EG–396 AX1–92 AX1–96 IDL switch circuit Park/neutral position switch circuit Stop light circuit AX1–88 Shift solenoid valve SL circuit Symptom AX1–90 AX1–84 Shift solenoid valve No.1, No.2 circuit Suspect Area Throttle position sensor circuit AX1–80 See page Vehicle speed sensor circuit Chapter 1. Electronic Circuit AX1–70 AX1–72 OFF–Vehicle repair matrix chart EG–318 EG–356 On–Vehicle repair matrix chart ECM Engine coolant temperature sensor circuit AX1–108 AX1–102 O/D switch and O/D OFF indicator switch circuit O/D cancel signal circuit AX1–98 Pattern select switch circuit AUTOMATIC TRANSAXLE – TROUBLESHOOTING AX1–69 AX1–70 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Vehicle does not move in R position Vehicle does not move in any forward position or reverse position No lock–up No lock–up OFF No kick–down No engine braking 2nd 1st
2nd No up–shift 3rd
2nd 3rd
O/D O/D
3rd No down–shift 3rd
2nd 2nd
1st N
R N
D N
L 1 st
2nd (D position 1 st
2nd (2 position) Harsh engagement 1 st
2nd
3rd 1st
2nd
3rd
O/D 2nd
3rd 3rd
O/D O/D
3rd 3rd
2nd Sliper shudder in forward and reverse (Directry after E/G start) C2 accumulator B2 accumulator. C, accumulator 3–4 shift valve 2–3 shift valve 1–2 shift valve Symptom Oil strainer Suspect Area Manual valve See page AX1–13 Chapter 2. On–Vehicle Repair (*:’94 A140E AUTOMATIC TRANSAXLE Repair Manual) OFF–vehicle repair matrix chart AX1–72 – Primary regulator valve Cut back valve Throttle valve Lock–up relay valve Throttle modulator valve 2nd modulator valve Low modulator valve Accumulator control valve Co accumulator Bo accumulator AUTOMATIC TRANSAXLE TROUBLESHOOTING AX1–71 AX1–72 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Vehicle does not move in any forward position Vehicle does not move in reverse position Vehicle does not move in any forward position and reverse position No lock–up No lock–up OFF Large shock during lock–up E/G stalls when starting off and stopping 1 st
2nd No up–shift 2nd
3rd 3rd ± O/D No down shift 2nd
1 st N
R N
D Harsh engagement 1 st
2nd (D position) 2nd
3rd 3rd
O/D Forward and reverse (After warm–up) Forward and reverse (Directly after E/G start) R position 1 St Slip or shudder 2nd 2nd
3rd (Up–shift 3rd O/D 1 st
3rd No engine braking 2nd All positions O/D Other than O/D Poor acceleration Other than 2nd 1st and 2nd 1st and R position R position Bo O/D brake C, Direct clutch C, Forward clutch Co O/D direct clutch Symptom Parking lock pawl Suspect Area Torque converter clutch See page AX1–34 Chapter 3. Off–Vehicle Repair (*:’94 A140E AUTOMATIC TRANSAXLE Repair Manual) Rear planetary gear Front planetary gear O/D planetary gear F2 No.2 one–way clutch F, No.1 one–way clutch FO O/D one–way clutch B2 Second brake B31 st and reverse brake B, 2nd coast brake AUTOMATIC TRANSAXLE – TROUBLESHOOTING AX1–73 AX1–74 AUTOMATIC TRANSAXLE – LOCATION OF CONNECTORS Location of Connectors in Engine Compartment TROUBLESHOOTING AX1–75 AUTOMATIC TRANSAXLE Location of Connectors in Body Sedan Coupe – TROUBLESHOOTING AX1–76 AUTOMATIC TRANSAXLE Wagon – TROUBLESHOOTING AX1–77 AUTOMATIC TRANSAXLE Location of Connectors in Instrument Panel – TROUBLESHOOTING AX1–78 AUTOMATIC TRANSAXLE – TROUBLESHOOTING AX1–79 AUTOMATIC TRANSAXLE J/B No–1 J/B No.3 – TROUBLESHOOTING AX1–80 AUTOMATIC TRANSAXLE – TROUBLESHOOTING CIRCUIT INSPECTION Diag. Trouble Code 42 No.1 Vehicle Speed Sensor Circuit CIRCUIT DESCRIPTION The No. 1 vehicle speed sensor outputs a 4–pulse signal for every revolution of the differential case. After this signal has been converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. DTC No. Diagnostic Trouble Code Detection Condition If the vehicle speed sensor signal is not input for 2 seconds or longer after condition A or B (described below) occurs, DTC 42 is recorded and the OD OFF indicator light lights up simultaneously. CONDITION A • 30 seconds or more elapses after the park/ neutral position switch goes OFF. • The throttle opening ratio and engine RPM are within the shadded area. Trouble Area • • • • Vehicle speed sensor Combination meter Harness or connector between vehicle speed sensor and ECM ECM CONDITION B Throttle Opening Ratio • 1 second or more elapses after the park/neutral position switch goes OFF. • A vehicle speed sensor signal of 14 km/h ($.7 mph) or more was input. • The stop light switch is OFF (brake pedal is released). voi 547 • Waveform between terminals SPD and E1 when vehicle speed is approx. 20 km/h (12 MPH). HINT: The greater the vehicle speed, the greater the number of vehicle speed sensor signals produced. AX1–81 AUTOMATIC TRANSAXLE – TROUBLESHOOTING CIRCUIT DESCRIPTION Fail Safe Function If the vehicle speed sensor fails, shift control takes place so that the throttle opening ratio and RPM are controlled according to the shift control map. DIAGNOSTIC CHART 5 V Fixed Measure voltage between terminal SPD of combination meter connector and body ground. 0 V Fixed Check speedometer circuit. See combination meter troubleshooting on B E section. Changes 0V
H5V Replace ECM. Measure voltage between terminals SPD and E1 of ECM connector. Check and repair harness or connector between combination meter and ECM. WIRING DIAGRAM Replace–ECM. AX1–82 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Measure voltage between terminal S P D of combination meter connector and body ground. (a) Shift the shift lever to N position. (b) Jack up one of the front wheels. (c) Disconnect the cruise control ECU and PPS connectors. (d) Turn IG switch ON. Measure voltage between terminal SPD of com– bination meter connector and body ground when slowly turning the Jack up wheel. Voltage: Constantly 0 V...... Go to Next Step Constantly 4–6 V...... Go to NG 1 Changes 0 V H 4 H 6 V ..... Go to N G 2 NG1 Check combination meter circuit. See combination meter troubleshooting. NG2 Replace ECM. Measure voltage between terminals SPD and E, of ECM. (1) Disconnect combination meter and cruise control ECU connectors. (2) Turn IG switch ON. (3) Measure voltage between terminals SPD and E, of ECM connector. Voltage: 4–6 V Replace ECM. Check and repair harness or connector between com bination meter and ECM. AUTOMATIC TRANSAXLE -Memo – TROUBLESHOOTING AX1–84 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Diag. Trouble Code 62 63 Shift Solenoid Valve No–1 and No.2 Circuit CIRCUIT DESCRIPTION Shifting from 1 st to O/D is performed in combination with ON and OFF of the shift solenoid valves No.1 and No.2 controlled by the ECM. If an open or short circuit occurs in either of the solenoid valves, the ECM controls the remaining normal solenoid to allow the vehicle to be operated smoothly (Fail safe function). Fail Safe Function If either of the solenoid valve circuits develops a short or an open, the ECM turns the other solenoid ON and OFF to shift to the gear positions shown in the table below. The ECM also turns the lock–up solenoid valve OFF at this time. If both solenoids malfunction, hydraulic control cannot be performed electronically and must be done manually. Manual shifting as shown in the following table must be done. (in the case of a short circuit, the ECM stops sending current to the short circuited solenoid). SOLENOID VALVE NO.1 MALFUNCTIONING NORMAL Position Solenoid valve No. 1 No. 2 Gear Solenoid valve No. 1 OFF OFF No. 1 Gear No.2 BOTH SOLENOID VALVES MALFUNCTIONING Gear when shift selector is manually operated 3rd 2nd 3rd 3rd O/D OFF OFF O/D OFF O/D O/D 3rd OFF O/D O/D O/D OFF O/D O/D 3rd OFF 3rd 3rd 3rd OFF 3rd 3 rd 3rd 2nd OFF Solenoid valve No. 2 OFF OFF Gear SOLENOID VALVE N0.2 MALFUNCTIONING 3rd OFF 3rd OFF 2nd 2nd x : Malfunctions Check the shift solenoid valve No.1 when diagnostic trouble code 62 is output and check the shift solenoid valve No.2 when diagnostic trouble code 63 is output. Code No. 62,63 Diag. Trouble Code Detection Condition (a) Solenoid resistance is 8
or lower (short circuit) when solenoid is energized. (b) Solenoid resistance is 100 k
or higher (open circuit) when solenoid is not energized. The ECM checks for an open or short circuit in the shift solenoid valve No–1 and No.2 circuit when it changes gear position. The ECM records diag. trouble code 62 or 63 if condi tion (a) or (b) is detected once, but it does not blink the O/D OFF indicator light. After the ECM detects condition (a) or (b) con– tinuously 8 times or more, it cancels the O/D OFF indi cator light to blink until condition (a) or (b) disappears After that, if the ECM detects condition (a) or (b) once, it starts blinking the O/D OFF indi– cator light again. Trouble area • • • Shift solenoid valve No.1 or No.2 Harness or connector between shift solenoid valve No.1 or No.2 and ECM connector ECM AX1–85 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC CHART Measure resistance between .terminals of electronically controlled transaxle solenoid connector and body ground. Check shift solenoid valve No.1 or No.2 in transaxle. Repair or replace malfunctioned part. Check harness and connector between electronically controlled transaxle solenoid connector and ECM. Repair or replace harness or con– nector. Replace ECM. WIRING DIAGRAM AX1–86 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECT ION PROCEDURE Measure resistance between terminals of electronically controlled transaxle solenoid connector and body ground. Disconnect electronically controlled transaxle so– lenoid connector. Measure resistance between terminals of elec– tronically controlled transaxle solenoid connector and body ground as shown in the illustration. Resistance: 1, 2–Body ground 11–15 0 Go to step Check shift solenoid valve No.1 or No.2 in transaxle. (1) Jack up the vehicle. (2) Remove oil pan. (1) Check shift solenoid valve No.1 and No.2 connector connection. (2) Measure resistance between shift solenoid valve No.1 and No.2 connector terminals and body ground. Resistance: 11–15
Check for operation sound of solenoids sound when you apply battery voltage to shift solenoid valve No.1 and No.2 connector terminals and body ground. Check continuity of solenoid wire. Continuity (Below 1
) Repair or replace malfunctioned part. Check harness and connector between electronically controlled transaxle solenoid connector and ECM. Repair or replace harness or connector. Replace ECM. AUTOMATIC TRANSAXLE -Memo – TROUBLESHOOTING AX1–88 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Diag. Trouble Code 64 Shift Solenoid Valve SL Circuit CIRCUIT DESCRIPTION The shift solenoid valve SL is turned ON and OFF by signals from the ECM to control the hydraulic pressure acting on the lock–up relay valve, which then controls operation of the lock–up clutch. If a malfunction occurs in this circuit and diagnostic trouble code 64 is stored in memory, the O/D OFF indicator light does not blink. Fail Safe Function If the ECM detects a malfunction, it turns the lock–up solenoid valve OFF. Code No. Diag. Trouble Code Detection Condition (a) Solenoid resistance is 8
or lower (short circuit) when solenoid energized. (b) Solenoid resistance is 100 k
or higher (open circuit) when solenoid is not energized. ECM memorizes diag. trouble code 64 if above (a) or (b) condition is detected once or more, but ECM does not start O/D OFF indicator light blinking. Trouble area • • • Shift solenoid valve SL Harness or connector between shift solenoid valve SL and ECM ECM DIAGNOSTIC CHART Check shift solenoid valve SL. Repair or replace malfunctioned part. Check harness and connector between electronically controlled transaxle solenoid connector and ECM. Repair or replace harness or connector. Replace ECM. WIRING DIAGRAM AX1–89 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check shift solenoid valve SL. (1) Check shift solenoid valve SL connector connection. (2) Measure resistance between shift solenoid valve SL connector terminals and body ground. Resistance: 11–15
Check that shift solenoid valve SL makes opera– tion sound when apply battery voltage shift so– lenoid valve SL connector terminal and body ground. Check continuity of solenoid wire. Continuity (Below 1
) Repair or replace malfunctioned part. Check harness and connector between electronically controlled transaxle solenoid connector–and ECM. Repair or replace harness or connector. Replace ECM. AX1–90 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Throttle Position Sensor Circuit CIRCUIT DESCRIPTION. The throttle position sensor detects the throttle valve opening angle and sends signals to the ECM. DIAGNOSTIC CHART Throttle position signal check. Proceed to next circuit inspection shown on matrix chart (See page AX1–68). Check throttle position sensor. Replace throttle position sensor. Check harness and connector between ECM and throttle position sensor (See page IN–31). Repair or replace harness or con– nector. Check and replace ECM. WIRING DIAGRAM AX1–91 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Throttle position signal check. Turn ignition switch ON (Do not start the engine). Check voltage at terminal TT of the DLC2 while gradually depressing the accelerator pedal from the fully closed position to the fully opened position. Voltage changes from 0 V to 8 V by stages. Do not depress the brake pedal during this test. The voltage will stay at 0 V if it is depressed. Proceed to next circuit inspection shown on matrix chart (See page AX1–68). Check throttle position sensor. See engine troubleshooting section on page EG–376. Replace throttle position sensor. Check harness and connector between ECM and throttle position sensor (See page IN–31). Repair or replace harness or connector. Check and replace ECM. AX1–92 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Park Neutral Position Switch Circuit CIRCUIT DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to the ECM. The ECM receives signals (NSW, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in the D position. DIAGNOSTIC CHART Check voltage between terminals NSW, 2, L of ECM connector and body ground. Proceed to next circuit inspection shown on matrix chart (See page AX1–68). Check park/neutral position switch. Replace park/neutral position switch. Check harness and connector between ECM and park/neutral position switch, park/neutral position switch and battery (See page IN–31). Repair or replace harness or con– nector. Check and replace ECM. AX1–93 AUTOMATIC TRANSAXLE WIRING DIAGRAM – TROUBLESHOOTING AX1–94 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminals NSW, 2, L of ECM connector and body ground. Turn ignition switch ON. Measure voltage between terminals NSW, 2, L of ECM connector and body ground when the shift lever is put in the following positions. Position P, N NSW–body ground Below 1 V 10–14 V* 2–body ground Below 1 V L–body ground Below 1 V Below 1 V Below 1 V 10–14 V Below 1 V Below 1 V 10–14 V 10–14V Below 1 V 10–14 V Below 1 V 10–14 V *: The voltage will drop slightly due to lighting up of the back up light. Proceed to next circuit inspection shown on matrix chart (See page AX1–68). Check park/neutral position switch. Remove park/neutral position switch. Check continuity between each terminal shown be– low when the shift lever is put in each position. Continuity Terminal Shift Position Replace park/neutral position switch. Check harness and connector between ECM and park/neutral position switch, park/neutral position switch and battery (See page IN–31). Repair or replace harness or connector. Check and replace ECM. AUTOMATIC TRANSAXLE -Memo – TROUBLESHOOTING AX1–96 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Stop Light Circuit CIRCUIT DESCRIPTION The purpose of this circuit is to prevent the engine from stalling when the brakes are suddenly applied while driving in lock–up condition. When the brake pedal is operated, this switch sends a signal to the ECM. Then the ECM cancels opera– tion of the lock–up clutch while braking is in progress. DIAGNOSTIC CHART Check operation of stop light. Check and repair stop light circuit (See page BE–62). Check stop light signal. Proceed to next circuit inspection shown on matrix chart (See page AX1–50). Check harness and connector between ECM and stop light switch (See page IN–31) . Repair or replace harness of con– nector. Check and replace ECM. WIRING DIAGRAM AX1–97 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check operation of stop light. Check if the stop light goes on and off normally when the brake pedal is depressed and released . Check and repair stop light circuit (See page BE–50) Check stop light signal. (1) Connect voltmeter to terminals TT and E l of the DLC2. (2) Turn ignition switch ON (Do not start the engine). (3) Fully depress the accelerator pedal until the voltmeter indicates 8 v and hold it. (4) Depress and release the brake pedal and check the voltage. Brake pedal Voltage Depressed Released Proceed to next circuit inspection shown on matrix chart (See page AX1–68). Check harness and connector between ECM and stop light switch (See page IN–31). Repair or replace harness or connector. Check and replace ECM. AX1–98 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Pattern Select Switch Circuit The ECM has stored in its memory the gear shift patterns for D position, 2nd position and L position, and also the lock–up pattern for D position. Two types of gear shifting pattern and lock–up pattern are recorded for D position; for POWER use and NORMAL use. The ECM selects the D position gear shift pattern and lock–up pattern in accordance with the signal from the pattern select switch. Check shift pattern switch operation. Proceed to next circuit inspection shown on matrix chart (See page AX1–68). Check PWR indicator light. Measure voltage between terminal 6 of pattern select switch connector and body ground. Check and repair pattern select switch power source circuit. Check pattern select switch. Replace pattern select switch. Check connectors and harness between pat– tern select switch, PWR indicator light and ECM. Replace ECM. Repair or replace connector as harness. AX1–99 AUTOMATIC TRANSAXLE WIRING DIAGRAM – TROUBLESHOOTING AX1–100 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check shift pattern switch operation. Check that the shift point changes when the pattern select switch is operated. Proceed to next circuit inspection shown on matrix chart (See page AX1–68). Check PWR indicator light. Turn IG switch 4N. Check that the PWR indicator light lights up when you push the pattern select switch to PWR. Go to step Measure voltage between terminal 6 of pattern select switch and body ground. (1) Push pattern select switch to NORMAL. (2) Turn IG switch ON. Measure voltage between terminal 6 of pattern select switch connector and body ground. Voltage: 10–14 V Check and repair pattern select switch power source circuit. AX1–101 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check pattern select switch. Disconnect pattern select switch connector. Measure resistance between terminals 3 and6 of pattern select switch connector when the select switch is set to PWR and NORMAL positions. Pattern PW R NORM Resistance 0
(continuity)

(open) Replace pattern select switch. Check connectors and harness between pattern select switch, PWR indicator light and ECM (See page IN–31). Repair or replace harness or connector. Replace ECM. AX1–102 AUTOMATIC TRANSAXLE – TROUBLESHOOTING O–D Main Switch & O–D OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go off when the switch is pushed in and come on when it is pushed out. In O/D main switch OFF position, the O/D OFF indicator lights up, and the ECM prohibits shifting to overdrive. The ECM also causes the O/D OFF indicator light to blink when a malfunction is detected. However, when the O/D main switch is OFF, the O/D indicator light does not blink, but stays on. In this case, connecting the terminals in the DLC2 or DLC1 can display the malfunction code. DIAGNOSTIC CHART See next page. WIRING DIAGRAM AX1–103 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC CHART Check O/D OFF indicator light while engine starting. Check O/D main switch operation. Proceed to next circuit inspection shown on matrix chart (See page AX1–68). Measure voltage between terminal 1 of O/D main switch and body ground. Repair or replace harness or connec– tor between combination meter and O/D main switch. Check O/D main switch. Repair or replace harness or connec– tor between O/D main switch and body ground. Remains OFF Remains ON Replace O/D main switch. Check O/D OFF indicator light when O/D main switch connector is disconnected. Replace O/D main switch. Check O/D OFF indicator light when ECM (inc. OD2 terminal) is disconnected. Replace ECM. Check harness between combination meter, O/D main switch and ECM. Repair or replace harness. Repair or replace combination meter. Check indicator lights on combination meter other than O/D OFF indicator light. Check and repair power source cir– cuit to combination meter. Check O/D main switch operation. Check and repair harness between O/D main switch and combination meter. Check harnesses between connector between combination meter and ECM. Repair or replace harness or con– nector. Replace ECM. AX1–104 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check 0 /D OFF indicator light when engine starting. When starting the engine, check the operating con– dition of the O/D OFF indicator light. O/D OFF indicator lights immediately after the engine is started. Remains ON..... NG 1 Remains OFF.... NG2 If the O/D OFF indicator light keeps blinking, check the diag. trouble code and repair the problem. NG1 Go to step NG2 Go to stop Check O/D main switch operation. (1) Turn ignition switch ON. (2) Check–O/D OFF” light when O/D main switch is pushed in to ON. (3) Start the engine. “O/D OFF” light goes off. (3) Check “O/D OFF” light when O/D main switch is pushed again, to OFF. “O/D OFF” light lights up. If the–O/D OFF” light blinks when the O/D main switch is pushed in to ON, a malfunction is occur– ing in the system. Check the diagnostic trouble code. Proceed to next circuit inspection shown on matrix chart (See page AX1–68). AX1–105 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Measure voltage between terminal 1 of O/D main switch connector and body ground. (1) Disconnect O/D main switch connector. (2) Turn IG switch ON. Measure voltage between terminal 1 of O/D main switch harness side connector and body ground. Voltage: 10–14 V Repair or replace harness or connector be– tween combination meter and O/D main switch. Check continuity of O/D main switch. Disconnect O/D main switch connector. Check continuity between terminals 1 and 3 of O/D main switch connector. ON Position: No continuity (More than 10 k
) OFF Position: Continuity (Below 1
) Replace O/D main switch. Repair or replace harness or connector between O/D main switch and body ground. AX1–106 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check O/D OFF indicator light when you disconnect O/D main switch connector. Turn IG switch ON. Check that the O/D OFF indicator light goes off when you disconnect the O/D main switch con– nector. Replace O/D main switch. Check 0 /D OFF indicator light when you disconnect ECM connector (including OD2 terminal). Turn IG switch ON. Check that the O/D OFF indicator light goes off when you disconnect the ECM connector (includ– ing OD2 terminal). Replace ECM. Check harness between combination meter, O/D main switch and ECM. Repair or replace harness. Repair or replace combination meter (See page BE–65). AX1–107 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check indicator lights on combination meter other than O/D OFF indicator light. Turn IG switch ON. Check the following indicator lights on combination meter: • Check Engine Light • Low Oil Pressure Warning Light • ABS Warning Light etc. Above indicator lights light up. Check and repair power source circuit to combination meter, or combination meter. Check O/D main switch operation. (1) Turn ignition switch ON. (2) Check–O/D OFF” light when O/D main switch is pushed in to ON. (3) Start the engine. “O/D OFF” light goes off. (3) Check “O/D OFF” light when O/D main switch is pushed again, to OFF. “O/D OFF” light lights up. If the–O/D OFF” light blinks when the O/D main switch is pushed in to ON, a malfunction is occur– ing in the system. Check the diagnostic trouble code. Check and repair harness between O/D main switch and combination meter. Check harness and connector between combination meter and ECM. Repair or replace harness or connector. Replace ECM. AX1–108 AUTOMATIC TRANSAXLE – TROUBLESHOOTING O–D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving with cruise control activated, in order to minimize gear shifting and provide smooth cruising uphill, overdrive may be prohibited temporarily in some conditions. The cruise control ECU sends OD cut signals to the ECM as necessary and the ECM cancels overdrive shifting until these signals are disconnected. DIAGNOSTIC CHART Check voltage between terminals OD 1 of ECM connector and body ground. Proceed to next circuit inspection shown on matrix chart (See page AX1–68). Check voltage between terminal OD of cruise control ECU harness side connector and body ground. Check and replace cruise control ECU. Check harness and connector between cruise control ECU and ECM (See page IN–31). Repair on replace harness or con– nector. Check and replace ECM. WIRING DIAGRAM AX1–109 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminal OD1 of ECM connector and body ground. Turn ignition switch ON. Measure voltage between terminal 01 31 of ECM connector and body ground. Voltage: 10–14 V Proceed to next circuit inspection shown on matrix chart (See page AX1–68). Check voltage between terminal OD of cruise control ECU harness side con– nector and body ground. (1) Disconnect cruise control ECU connector. (2) Turn ignition switch ON. Measure voltage between terminal OD of cruise control ECU harness side connector and body ground. Voltage: 10–14 V Check and replace cruise control ECU. Check harness or connector between cruise control ECU and ECM (See page IN–31). ’OK Check and replace ECM. Repair or replace harness or connector. AX1–110 AUTOMATIC TRANSAXLE – TROUBLESHOOTING TE1 Terminal Circuit CIRCUIT DESCRIPTION The ECM displays diagnostic trouble codes using the O/D OFF indicator light when terminals TE1 and E1 of the DLC2 or DLC1 are connected. DIAGNOSTIC CHART Check voltage between terminals TE1 and E1 of DLC2 or DLC1. Proceed to next circuit inspection shown on matrix chart (See page AX1–68). Check harness and connector between ECM and DLC2, DLC1 and body ground (See page IN–31). Repair or replace harness or con– nector. Check and replace ECM. WIRING DIAGRAM AX1–111 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminals TE, and E, of DLCZ or DLC1. Measure voltage between terminals TE, and E, of DLC2 or D LC1. Voltage: 4–6 V Proceed to next circuit inspection shown on matrix chart (See page AX1–68). Check harness and connector between ECM and DLC2, DLC1 and body ground (See page IN–31). Repair or replace harness or connector. Check and replace ECM. AX1–112 AUTOMATIC TRANSAXLE – TROUBLESHOOTING TT Terminal Circuit CIRCUIT DESCRIPTION Checks of ECM input and output signals related to the throttle position sensor, brakes, shift position and other circuits can be performed by measuring the voltages at terminal T, of DLC1. DIAGNOSTIC CHART Check harness and connector between ECM and DLC2, DLC1 and body. ground (See page IN–31). Check and replace ECM. WIRING DIAGRAM Repair or replace harness or con– nector. AX1–113 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA Engine idling D position R position AT stall D position R position Line pressure (whell locked) Engine stall revolution Time lag Engine idle speed (Cooling fan and A/C OFF) N position Throttle cable adjustment (Throttle valve fully opened) Limit Limit Torque converter runout Drive plate runout SHIFT POINT Shifting point Shift position D position 2 position L position LOCK–UP POINT D position km/h (mph) Throttle valve opening 596 ’3rd Gear (O/D switch OFF) O/D Gear ’O/D switch OFF NORM PW R Vehicle speed km/h (mph) AX1–114 AUTOMATIC TRANSAXLE TORQUE SPECIFICATIONS Part tightened Engine rear mounting bracket x Front suspention member Engine rear mounting bracket x Front suspention member LH transaxle mounting Transaxle x Engine 12 mm bolt Transaxle x Engine 10 mm bolt Torque converter clutch x Drive plate Valve body x Transaxle case Oil strainer Oil pan Oil pan drain plug Testing plug Transaxle rear cover x Transaxle case Park/neutral position switch x Transaxle case (bolt) Park/neutral position switch (nut) – SERVICE SPECIFICATIONS AX2–1 AUTOMATIC TRANSAXLE – A541E AUTOMATIC TRANSAXLE AX2–2 AUTOMATIC TRANSAXLE – DESCRIPTION DESCRIPTION GENERAL DESCRIPTION The ’94 model years A541 E automatic transaxle is a revised version of the previous model year’s A540E automatic transaxle. The following changes have been made to match the brand new 1 MZ –FE engine: • Adoption of an Electronically Controlled Transaxle with an intelligent control system. This version has evolved from the previous electronically Controlled Transaxle system. • The hydraulic pressure contrl system has been revised accordingly. • The torque converter clutch and the gear train have been revised. AX2–3 AUTOMATIC TRANSAXLE – GENERAL SPECIFICATIONS Type of Transaxle Type of Engine Torque Converter Clutch Stall Torque Ratio Torque Converter Clutch Lock–up Mechanism Gear Ratio Transaxle B, Band Width 1 st Gear 2nd Gear 3rd Gear O/D Gear Reverse Gear Number of Discs and Plates 0/D Direct Clutch (Co) Forward Clutch (C,) . Direct Clutch (Ct) 2nd Brake (B:j First and Reverse Brake (Bj O/D Brake (Bo) mm (in.) ATF Type Capacity liter (US qts, Imp.qts) A/T D/F DESCRIPTION AX2–4 AUTOMATIC TRANSAXLE – OPERATION OPERATION 1. MECHANICAL OPERATION p . . . . . Operating Shift lever position Gear Position Parking Reverse Neutral 1 st 2nd 3rd O/D 1 st 2nd *3rd 1 St ‘2nd *Down–shift only – no up–shift AX2–5 AUTOMATIC TRANSAXLE – OPERATION 2. FUNCTION OF COMPONENTS COMPONENT FUNCTION Forward Clutch Connects input shaft and front planetary ring gear Direct Clutch Connects input shaft and front & rear planetary sun gear 2nd Coast Brake Prevents front & rear planetary sun gear from turning either clockwise or counterclockwi 2nd Brake Prevents outer race o I from turning either clockwise or counterclockwise, thus preventing front & rear planetary sun gear from turning counterclockwise 1 st & Reverse Brake Prevents rear planetary carrier from turning either clockwise or counterclockwise No. 1 One–Way Clutch When BZ is operating, prevents front & rear planetary sun gear from turning counterclockwise . No.2 One–Way Clutch Prevents rear .planetary carrier from turning counterclockwise O/D Direct Clutch Connects overdrive sun gear and overdrive planetary carrier O/D Brake Prevents overdrive sun gear from turning either clockwise or counterclockwise O/D One–Way Clutch Planetary Gears When transaxle is– being driven by engine, connects overdrive sun gear and overdrive carrier These gears change the route through which driving force is transmitted in accor– dance with the operation of each clutch and brake in order to increase or reduce the in– put and output speed AX2–6 AUTOMATIC TRANSAXLE – OPERATION Power from the engine transmitted to the input shaft via the torque converter clutch is then transmitted to the planetary gears by the operation of the clutch. By operation of the brake and one–way clutch, either the planetary carrier or the planetary sun gear are immobilized, altering the speed of revolution of the planetary gear unit. Shift change is carried out by altering the combination of clutch and brake operation. Each clutch and brake operates by hydraulic pressure; gear position is decided according to the throttle opening angle and vehicle speed, and shift change automatically occurs. The conditions of operation for each gear position are shown on the following illustrations: D or 2 Position 1 st Gear 2 Position 2nd Gear D Position 2nd Gear L Position 1 st Gear D Position 3rd Gear R Position Reverse Gear D Position O/D Gear AX2–7 AUTOMATIC TRANSAXLE – OPERATION 3. HYDRAULIC CONTROL SYSTEM The hydraulic control system is composed of the oil pump, the valve body, the solenoid valves, the accumulators, the clutches and brakes as well as the fluid passagas which connect all of these components. Based on the hydraulic pressure created by the oil pump, the hydraulic control system governs the hydraulic pressure acting on the torque converter clutch, clutches and brakes in accordance with the vehicle driving conditions. There are three solenoid valves on the valve body. The No. 1 and No.2 solenoid vales are turned on and off by signals from the ECM to operate the shift valves and change the gear shift position. The SL solenoid valve is operated by signals from the ECM to engage or disengage the lock –up clutch of the torque converter clutch. The SLN solenoid valve is operated by signals from the ECM to control the engagement speed and reduce gear shift shock. AX2–8 AUTOMATIC TRANSAXLE – OPERATION 4. ELECTRONIC CONTROL SYSTEM GENERAL The electronic control system for the A541 E automatic transaxte provides extremely precise control of the gear shift timing and lock–up timing in response to driving conditions as sensed by various sensors located throughout the vehicle and in response to the engine’s running condition. At the same time, the ECM control reduces vehicle squat when the vehicle starts out and gear shift shock. The electronic control system is also equipped with a self diagnosis system which diagnoses malfunctions of electronically controlled components and warns the driver, and a fail–safe system which makes it possible for the vehicle to continue functioning when a malfunction occurs. CONSTRUCTION The electronic control system can be broadly divided into three groups; the sensors, ECM, and actuators. SENSORS ECM S Crankshaft Position Sensor • Engine Speed Sensor Throttle Position Sensor • Idling Signal • Throttle Position Signal ACTUATORS SZ IDL,VTA SL Shift Solenoid Valve No. 1 Shift Solenoid Valve No.2 Shift Solenoid Valve SL SLN Shift Solenoid Valve SLN Engine Coolant Temp. Sensor Engine Torque Control (ESA) Park/Neutral Position Switch • Neutral Start Signal • Shift Lever Position Signal NSW, R 2., L No. 1 Vehicle Speed Sensor Combination Meter Direct Clutch Speed Sensor Ignition Coils SP 1 Stop Light Switch Cruise Control ECU Spark Plugs NC O/D OFF indicator Light Pattern Select Switch O/D Main Switch Igniter OOD2 STP OD 1 Data Link Connector 3 (For OBD2) AX2–9 AUTOMATIC TRANSAXLE ARRANGEMENT OF COMPONENTS – OPERATION AX2–10 AUTOMATIC TRANSAXLE No. Components Park/Neutral Position Switch – OPERATION functions Detects the shift lever position. Direct Clutch Speed Sensor Detects the input shaft speed from 1 st gear to 3rd gear. Shift Solenoid Valve SL Controls the hydraulic pressure applied to the lock–up clutch and controls lock–up timing. Shift Solenoid Valve SLN Controls the hydraulic pressure applied to the back cham– ber of the accumulator and smooths the engagement of clutches and brakes during shifting . Shift Solenoid Valve No. 1 and No.2 Controls the hydraulic pressure applied to each shift valve, and control the gear shift position and timing. Stop Light Switch Detects if the brake pedal is depressed. Vehicle Speed Sensor Detects and sends a vehicle speed signal to the ECM. Pattern Select Switch Selects the Power mode or the Normal mode for shift and lock–up timing. 0/D OFF Indicator Light Blinks and warns the driver, while the 0/D main switch is pushed in, when the electronic control circuit is malfunc– tioning. ’ O/D Switch Prevents up–shift to the O/D gear if the O/D switch is off. ECM Controls the engine and transaxle actuators based on signals from each sensor. Throttle Position Sensor Detects the throttle valve opening angle. Engine Coolant Temp. Sensor Detects the engine coolant temperature. Cruise Control ECU This ECM prevents the transaxle from shifting into over– drive and prohibits lock–up control when the vehicle’s speed drops below the auto drive set speed parameter. Data Link Connector 3 By connecting the OBD II scan tool or TOYOTA hand– held tester the transaxle control data can be read. AX2–11 AUTOMATIC TRANSAXLE SYSTEM DIAGRAM – OPERATION AX2–12 AUTOMATIC TRANSAXLE – PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) 09043–38100 Hexagon 10 mm Wrench Remove and install oil pan drain plug. 09223–15010 Crankshaft Rear Oil Seal Replacer 09308–00010 Oil Seal Puller Remove side gear shaft oil seal. 09316–60010 Transmission & Transfer Bearing Reptacer Install RH side bearing to differential case. (09316–00010) Replacer Pipe Install right sid, gear shaft oil seal. 09350–32014 TOYOTA Automatic Transmission Tool Set (09351–32010) One–way Clutch Test Tool (09351–32020) Stator Stopper 09992–00094 Automatic Transmission Oil Pressure Gauge Set Line pressure AX2–13 AUTOMATIC TRANSAXLE – PREPARATION RECOMMENDED TOOLS 09031–00030 Pin Punch Pin diameter 3 mm(0.12 in.) 09082–00050 TOYOTA Electrical Tester Set EQUIPMENT Straight edge Check torque converter clutch installation. Vernier calipers Check torque converter clutch installation. Dial indicator or dial indicator with magnetic base Measure drive plate runout. Torque wrench LUBRICANT Item Automatic transaxle fluid (w/o Differential oil) Dry fill Drain and refill Differential Fluid Capacity 6.75 liters (7.1 US qts, 5.9 Imp. qts) 3.5 liters (3.7 US qts, 3.1 imp. qts) 0.85 liters (0.9 US qts, 0.7 Imp. qts) Classification ATF DEXRON’ II ATF DEXRON’ 1I SSM (Special Service Materials) 08833–00070 Adhesive 1311, THREE BOND 1311 or equivalent Torque converter clutch mounting bolt AX2–14 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR ON–VEHICLE REPAIR CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. VEHICLE SPEED SENSOR REPLACEMENT (w/Speedometer Driven Gear) 1. DISCONNECT VEHICLE SPEED SENSOR CONNEC– TOR 2. REMOVE VEHICLE SPEED SENSOR ASSEMBLY (a) Remove the bolt and vehicle speed sensor assembly. (b) Remove the clip and speedometer driven gear from vehicle speed sensor. (c) Remove the O–ring from vehicle speed sensor. 3. INSPECT VEHICLE SPEED SENSOR 4. INSTALL VEHICLE SPEED SENSOR ASSEMBLY (a) Coat a new 0–ring with ATF and install it to the vehicle speed sensor. (b) Install the speedometer driven gear to the vehicle speed sensor and clip. (c) Install the vehicle speed sensor assembly and torque the bolts. Torque: 16 N–m (160 kgf–cm. 12 ft–lbf) 5. CONNECT VEHICLE SPEED SENSOR CONNECTOR AX2–15 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR DIRECT CLUTCH SPEED SENSOR REPLACEMENT 1. DISCONNECT DIRECT CLUTCH SPEED SENSOR CONNECTOR 2. REMOVE DIRECT CLUTCH SPEED SENSOR (a) Remove the bolt and direct clutch speed sensor. (b) Remove the 0 –ring from direct clutch speed sensor. 3. INSPECT DIRECT CLUTCH SPEED SENSOR (See page AX2–108) 4. INSTALL DIRECT CLUTCH SPEED SENSOR (a) Coat a new 0–ring with ATF and install it to the direct clutch speed sensor. (b) Install the direct clutch speed sensor and torque the bolt. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) AX2–16 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR PARK/NEUTRAL POSITION SWITCH REPLACEMENT 1. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 2. REMOVE PARK/NEUTRAL POSITION SWITCH (a) Remove the clip from the shift control cable. (b) Remove the nut and control cable. (c) Remove the transaxle control shaft lever. (d) Remove the park/neutral position switch. 3. INSPECT PARK/NEUTRAL POSITION SWITCH (See page AX2–116) 4. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH (a) Install the park/neutral position switch. AX2–17 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR (b) Adjust the park/neutral position switch. (See page AX2–69) (c) Install the transaxle control shaft lever. (d) Install the control cable and nut. (e) Install the clip to the shift control cable. 5. CONNECT PARK/ NEUTRAL POSITION SWITCH CONNECTOR 6. TEST DRIVE VEHICLE AX2–18 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR VALVE BODY REMOVAL 1. CLEAN TRANSAXLE EXTERIOR To help prevent contamination, clean the exterior of the transaxle. 2. DRAIN TRANSAXLE FLUID Using SST, remove the drain plug and the fluid into suitable container. SST 09043 – 38100 3. REMOVE OIL PAN AND GASKET NOTICE: Some fluid will remain in the oil pan. Remove all pan bolts, and carefully remove the pan assembly. Discard the gasket. 4. EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect any steel chips. Look carefully at the chips and particles in the pan and the magnet to anticipate what type of wear you will find in the transaxle. Steel (magnetic): bearing, gear and plate wear Brass (non–magnetic): bushing wear 5. REMOVE OIL STRAINER AND APPLY TUBE BRACK– ET (a) Remove the 3 bolts and the oil strainer. NOTICE: Be careful as oil will come out of the strainer when it is removed. (b) Remove the 3 bolts and the apply tube bracket. 6. REMOVE OIL TUBES Pry up both tube ends with a large screwdriver and remove the 5 tubes. AX2–19 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR 7. DISCONNECT SOLENOID CONNECTORS 8. REMOVE TRANSFER LUBRICATION APPLY TUBE (a) Remove the 2 bolts and detent spring. (b) Remove the tube set bolts. (c) Pry up the tube with a screwdriver and remove the tube. 9. REMOVE MANUAL VALVE BODY Remove the 5 bolts and manual valve body. AX2–20 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR 10. REMOVE B3 APPLY TUBE (a) Remove the tube retainer. (b) Pry up the tube with a screwdriver and remove the tube. 11. REMOVE VALVE BODY (a) Remove the 11 bolts. (b) Disconnect the throttle cable from cam and remove the valve body. 12. REMOVE SECOND BRAKE APPLY GASKET AX2–21 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR VALVE BODY INSTALLATION 1. INSTALL NEW SECOND BRAKE APPLY GASKET 2. INSTALL VALVE BODY (a) While holding the cam down with your hand, slip the cable end into the slot. (b) Bring valve body into place. NOTICE: Be careful not to entangle the solenoid wire. (c) Finger tighten all bolts first. Then tighten them with a torque wrench. HINT: Each bolt length (mm, in.) is indicated in the illustration. Torque: 11 N–m (110 kgf–cm. 8 ft–lbf) 3. INSTALL 133 APPLY TUBE (a) Using a plastic hammer, install the tube into the posi– tion indicated in the illustration. NOTICE: Be careful not to bend or damage the tubs. (b) Install the tube retainer. HINT: The bolt length (mm, in.) is indicated in the illustration. Torque: 11 N–m (110 kgf–cm, 8 ft–lbf) 4. INSTALL MANUAL VALVE BODY (a) Align the manual valve with the pin on the manual valve lever. (b) Install the valve body into place. (c) Finger tighten the 5 bolts first. Then tighten them with a torque wrench. HINT: Each bolt length (mm, in.) is indicated in the illustration. Torque: 11 N–m (110 kgf–cm, 8 ft–lbf) AX2–22 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR 5. INSTALL TRANSFER LUBRICATION APPLY TUBE AND DETENT SPRING (a) Using a plastic hammer, install the tube into the posi– tion indicated in the illustration. NOTICE: Be careful not to bend or damage the tube. (b) Install the bolt. HINT: The bolt length (mm, in.) is indicated in the illustration. Torque: 11 N–m (170 kgf–cm, 8 ft–lbf) (c) Install the detent spring. HINT: Each bolt length (mm, in.) is indicated in the illustration. Torque: 11 N–m (110 kgf–cm, 8 ft–lbf) (d) Check that the manual valve lever is in contact with the center of the roller at the tip of the detent spring. 6. CONNECT SOLENOID CONNECTORS 7. INSTALL OIL TUBES (a) Using a plastic hammer, install the tubes into the positions indicated in the illustration. NOTICE: Be careful not to bend or damage the tubes. AX2–23 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR 8. INSTALL OIL STRAINER AND APPLY TUBE BRACK– ET Install the oil strainer. Torque: 11 N–m (110 kgf–cm, 8 ft–Ibf) Install the tube bracket. Torque: 10 N–m (100 kgf–cm, 7 ft–Ibf) HINT: Each bolt length (mm, in.) is indicated in the illustration. 9. INSTALL MAGNETS NOTICE: Make sure that the magnet does not interfere with the oil tubes. 10. INSTALL OIL PAN (a) Install a new gasket and oil pan. (b) Install and torque 17 bolts. Torque: 4.9 N–m (50 kgf–cm, 43 ft–lbf) 11. FILL TRANSAXLE WITH ATF NOTICE: Do not overfill. Fluid type: ATF DEXRON
II 12. CHECK FLUID LEVEL (See page AX2–68) AX2–24 AUTOMATIC TRANSAXLE – ON –VEHICLE REPAIR THROTTLE CABLE REMOVAL 1. DISCONNECT THROTTLE CABLE FROM ENGINE Disconnect the cable from the throttle linkage. 2. REMOVE PARK/NEUTRAL POSITION SWITCH (See page AX2–61) 3. REMOVE VALVE BODY (See page AX2–18) 4. REMOVE THROTTLE CABLE (a) Remove the bolt and retaining plate. (b) Pull out the cable from the transaxle case. THROTTLE CABLE INSTALLATION 1. INSTALL CABLE INTO TRANSAXLE CASE (a) Be sure to push it in all the way. (b) Install the retaining plate and bolt. 2. INSTALL VALVE BODY (See page AX2–21) 3. IF THROTTLE CABLE IS NEW, STAKE STOPPER OR PAINT MARK ON INNER CABLE HINT: New cables do not have a staked cable stopper. (a) Bend the cable so there is a radius of about 200 mm (7.87 in.). (b) Pull the inner cable lightly until a light resistance is felt, and hold it in position there. (c) Stake the stopper, 0.8–1.5 mm (0.031 –0.059 in.) from the end of outer cable. AX2–25 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR 4. CONNECT THROTTLE CABLE TO ENGINE 5. ADJUST THROTTLE CABLE (See page AX2–69) 6. INSTALL PARK/NEUTRAL POSITION SWITCH (See page AX2–16) 7. TEST DRIVE VEHICLE AX2–26 AUTOMATIC TRANSAXLE – ON–VEHICLE REPAIR SIDE GEAR SHAFT OIL SEAL REPLACEMENT 1. REMOVE BOTH DRIVE SHAFTS (See page SA–22) 2. REMOVE BOTH SIDE GEAR SHAFT OIL SEALS Using SST, pull out the oil seal. SST 09308–00010 3. INSTALL LEFT SIDE GEAR SHAFT OIL SEAL (a) Using SST, drive in a new oil seal. SST 09223–15010 Oil seal depth: 0 ± 0.5 mm (0 ± 0.02 in.) (b) Coat the lip of oil seal with MP grease. 4. INSTALL RIGHT SIDE GEAR SHAFT OIL SEAL (a) Using SST, drive in a new oil seal. SST 09316–60010 (09316–00010) Oil seal depth: 0 ± 0.5 mm (0 ± 0.02 in.) (b) Coat the lip of oil seal with MP grease. 5. INSTALL BOTH DRIVE SHAFTS (See page SA–25) 6. CHECK TRANSAXLE FLUID LEVEL (See page AX2–68) AX2–27 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION ASSEMBLY REMOVAL AND INSTALLATION Remove and install the parts as shown. AX2–28 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION TRANSAXLE REMOVAL 1. DISCONNECT AND REMOVE BATTERY 2. REMOVE AIR CLEANER ASSEMBLY 3. REMOVE THROTTLE CABLE FROM ENGINE 4. REMOVE CRUISE CONTROL ACTUATOR (a) Remove the cruise control actuator cover. (b) Disconnect the connector. (c) Remove the 3 bolts and cruise control actuator with bracket. 5. REMOVE GROUND TERMINAL 6. DISCONNECT VEHICLE SPEED SENSOR CONNEC– TOR 7. DISCONNECT DIRECT CLUTCH SPEED SENSOR CONNECTOR AX2–29 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 8. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 9. DISCONNECT SOLENOID CONNECTOR 10. DISCONNECT SHIFT CONTROL CABLE (a) Remove the clip from the shift control cable. (b) Remove the unit. 11. REMOVE EARTH CABLES 12. DISCONNECT OIL COOLER HOSE AX2–30 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 13. REMOVE 2 FRONT SIDE TRANSAXLE MOUNTING BOLTS 14. REMOVE 2 FRONT SIDE ENGINE MOUNTING BOLTS 15. REMOVE 2 OIL COOLER CLAMPING BOLTS FROM FRONT FRAME ASSEMBLY 16. REMOVE STARTER (a) Disconnect the connector and remove the nut. (b) Remove the 2 bolts and the starter. 17. REMOVE 4 UPPER TRANSAXLE TO ENGINE BOLTS AX2–31 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 18. INSTALL ENGINE SUPPORT FIXTURE 19. TIE STEERING GEAR HOUSING TO ENGINE SUP– PORT FIXTURE BY CODE OR EQUIVALENT 20. RAISE AND SUITABLY SUPPORT VEHICLE 21. REMOVE FRONT WHEEL 22. REMOVE EXHAUST FRONT PIPE (a) Remove the 2 bolts and exhaust front pipe clamp. (b) Remove the 4 nuts. (c) Remove the 2 bolts and exhaust front pipe support. (d) Remove the 2 bolts and nuts. (e) Remove the exhaust front pipe. 23. REMOVE DIFFERENTIAL FLUID DRAIN PLUG AND GASKET 24. DRAIN DIFFERENTIAL FLUID INTO A SUITABLE CONTAINER AX2–32 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 26. REMOVE RIGHT AND LEFT ENGINE SIDE COVER NO.2 26. REMOVE ENGINE UNDER FRONT COVER NO.1 AND NO.2 27. REMOVE DRIVE SHAFT (See page SA–22) 28. REMOVE FRONT SIDE ENGINE MOUNTING NUT 29. REMOVE REAR SIDE ENGINE MOUNTING BOLTS (a) Remove 2 hole plugs. (b) Remove 2 bolts and nuts. 30. REMOVE 4 LEFT SIDE TRANSAXLE MOUNTING BOLTS 31. REMOVE STEERING GEAR HOUSING (a) Remove the 4 bolts and disconnect the stabilizer bar bushing bracket from the front frame assembly. AX2–33 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION (b) Remove 2 bolts and nuts from the steering gear housing. (c) Remove the steering gear housing. 32. REMOVE FRONT FRAME ASSEMBLY (a) Hold the front frame assembly with a jack. (b) Remove 2 set screws from the right and left fender liners. (c) Remove 6 bolts and 4 nuts. (d) Remove the front frame assembly. 33. HOLD TRANSAXLE WITH A JACK 34. REMOVE TORQUE CONVERTER CLUTCH MOUNT– ING BOLTS (a) Remove the 2 bolts and hole cover. AX2–34 AUTOMATIC TRANSAXLE – r ASSEMBLY REMOVAL AND INSTALLATION (b) Turn the crankshaft to gain access to each bolt. (c) Hold the crankshaft pulley nut with a wrench and remove the 6 bolts. 35. REMOVE EXHAUST MANIFOLD PLATE 36. REMOVE TRANSAXLE TO ENGINE BOLTS 37. REMOVE TRANSAXLE ASSEMBLY Separate transaxle and engine, and lower the trans– axle. 38. REMOVE TORQUE CONVERTER CLUTCH FROM TRANSAXLE AX2–35 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION TORQUE CONVERTER CLUTCH AND DRIVE PLATE INSPECTION 1. INSPECT ONE–WAY CLUTCH (a) Install SST into the inner race of the one–way clutch. SST 09350–32014 (09351–32020) (b) Install SST so that it fits in the notch of the converter hub and outer race of the one–way clutch. SST 09350–32014 (09351 –32020) (c) With the torque converter clutch standing on its side, the clutch locks when turned counterclockwise, and rotates freely and smoothly clockwise. If necessary, clean the converter and retest the clutch. Replace the converter if the clutch still fails the test. 2. MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR Set up a dial indicator and measure the drive plate runout. If runout exceeds 0.20 mm (0.0079 in.) or if the ring gear is damaged replace the drive plate. If installing a new drive plate, note the orientation of spacers and tighten the bolts. Torque: 83 N–m (850 kgf–cm, 61 ft–lbf) AX2–36 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE RUNOUT (a) Temporarily mount the torque converter clutch to the drive plate. Set up a dial indicator. If runout exceeds 0.30 mm (0.0118 in.), try to correct by reorienting the installation of the converter. If ex– cessive runout cannot be corrected replace the torque converter clutch. HINT: Mark the position of the converter to ensure correct installation. (b) Remove the torque converter clutch. TRANSAXLE INSTALLATION 1. INSTALL TORQUE CONVERTER CLUTCH IN TRA– NSAXLE If the torque converter clutch has been drained and washed, refill with new ATF. Fluid type: ATF DEXRON II 2. CHECK TORQUE CONVERTER CLUTCH INSTALLA– TION Using calipers and a straight edge, measure from the installed surface to the front surface of the transaxle housing. Correct distance: More than 13.7 mm (0.539 in.) AX2–37 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 3. ALIGN TRANSAXLE AT INSTALLATION POSITION (a) Align the 2 knock pins on the block with the converter housing. (b) Temporarily install the bolt. 4. INSTALL TRANSAXLE TO ENGINE BOLTS Install the transaxle to engine bolts. 12 mm head bolt Torque: 64 N–m (650 kgf–cm, 47 ft–lbf) 10 mm head bolt Torque: 46 N–m (470 kgf–cm. 34 ft–lbf) 5. INSTALL EXHAUST MANIFOLD PLATE (a) Install the exhaust manifold plate. (b) Install and torque the bolt and nut. Torque: 20 N–m (200 kgf–cm, 14 ft–lbf) (c) Install and torque the nut. Torque: 20 N–m (200 kgf–cm, 14 ft–Ibf) 6. INSTALL TORQUE CONVERTER CLUTCH MOUNT– ING BOLTS (a) Clean the threads of the bolts with gasoline. (b) Coat the threads of the bolts with sealer. Sealer: Part No.08833–00070, THREE BOND 1324 or equi– valent (c) Tighten the bolts evenly. Torque: 27 N–m (280 kgf–cm, 20 ft–lbf) HINT: First install dark green colored bolt and then the 5 bolts. (d) Install the hole cover with 2 bolts. AX2–38 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 7. INSTALL FRONT FRAME ASSEMBLY (a) Hold the front frame assembly. (b) Install the6 bolts and 4 nuts. (c) Torque the bolts and nuts. 19 mm head bolt Torque: 1$1 N–m (1,850 kgf–cm, 134 ft–lbf) 12 mm head bolt Torque: 32 N–m (330 kgf–cm, 24 ft–lbf) Nut Torque: 36 N–m (370 kgf–cm, 27 ft–lbf) (d) Install the 2 set screws in the right and left fender liners. 8. INSTALL STEERING GEAR HOUSING (a) Install the steering gear housing to the front frame assembly. (b) Install and torque the 2 bolts and nuts. Torque: 181 N–m (1,850 kgf–cm, 134 ft–lbf) (c) Connect the stabilizer bar bushing bracket with the 4 bolts. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) AX2–39 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 9. INSTALL FOUR LEFT SIDE TRANSAXLE MOUNT– ING BOLTS Torque: 52 N–m (530 kgf–cm. 38 ft–lbf) 10. INSTALL REAR SIDE MOUNTING BOLTS AND NUTS (a) Install and torque the 2 bolts and nuts. Torque:66 N–m (670 kgf–cm, 48 ft–lbf) (b) Install 2 hole plugs. 11. INSTALL FRONT SIDE ENGINE MOUNTING NUT Torque: 80 N–m (820 kgf–cm, 59 ft–lbf) 12. INSTALL DRIVE SHAFT (See page SA–25) 13. INSTALL RIGHT AND LEFT ENGINE SIDE COVER NO.2 14. INSTALL ENGINE UNDER FRONT COVER NO.1 AND NO.2 15. INSTALL DIFFERENTIAL FLUID DRAIN PLUG WITH A NEW GASKET 16. FILL DIFFERENTIAL Fluid Type: ATF DEXRON II Capacity: 0.85 liters (0.9 US qts, 0.7 Imp. qts) 17. CHECK DIFFERENTIAL FLUID LEVEL AX2–40 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 18. INSTALL EXHAUST FRONT PIPE (a) Install a new gasket. (b) Install the exhaust front pipe. (c) Install and torque 2 bolts and new nuts. Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) (d) Install the exhaust front pipe support and 2 bolts. (e) Install 2 new gaskets. (f) Install and torque 4 new nuts. Torque: 62 N–m (630 kgf–cm, 46 ft–lbf) (g) Install the exhaust front pipe clamp and 2 bolts. Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) 19. INSTALL FRONT WHEEL AND LOWER VEHICLE Torque: 103 N–m (1,050 kgf–cm, 76 ft–lbf) 20. UNTIE STEERING GEAR HOUSING REMOVE ENGINE SUPPORT FIXTURE AX2–41 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 21. INSTALL 4 UPPER TRANSAXLE TO ENGINE BOLTS Torque: 64 N–m (650 kgf–cm, 47 ft–lbf) 22. INSTALL STARTER (a) Install the starter with the 2 bolts. (b) Torque the 2 bolts. Torque: 38 N–m (400 kgf–cm, 29 ft–lbf) (c) Connect the connector and install the nut. 23. INSTALL OIL COOLER CLAMPING BOLTS TO FRONT FRAME ASSEMBLY 24. INSTALL TWO FRONT SIDE ENGINE MOUNTING BOLTS Torque: 80 N–m (820 kgf–cm, 59 ft–lbf) 25. INSTALL TWO FRONT SIDE TRANSAXLE MOUNT– ING BOLTS Torque: 80 N–m (820 kgf–cm, 59 ft–lbf) AX2–42 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 26. CONNECT OIL COOLER HOSE 27. INSTALL EARTH CABLES 28. CONNECT SHIFT CONTROL CABLE (a) Install the clip from the shaft control cable. (b) Install and torque the nut. (c) Adjust the shift control cable. (See page AX2–69) 29. CONNECT SOLENOID CONNECTOR 30. CONNECT PARK/ NEUTRAL POSITION SWITCH CONNECTOR AX2–43 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 31. CONNECT DIRECT CLUTCH SPEED SENSOR CON– NECTOR 32. CONNECT VEHICLE SPEED SENSOR CONNECTOR 33. INSTALL GROUND TERMINAL 34. INSTALL CRUISE CONTROL ACTUATOR (a) Install the cruise control actuator with bracket the 3 bolts. (b) Connect the connector. (c) Install the cruise control actuator cover. 35. INSTALL THROTTLE CABLE TO ENGINE (a) Torque the nuts. Torque: 15 N–m (150 kgf–cm, 11 ft–lbf) (b) Adjust the throttle cable. (See page AX2–69) 36. INSTALL AIR CLEANER ASSEMBLY 37. INSTALL BATTERY AX2–44 AUTOMATIC TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 38. FILL TRANSAXLE WITH ATF AND CHECK FLUID LEVEL (See page AX2–68) NOTICE: Do not overfill. Fluid type: ATF DEXRONll 39. INSPECT FRONT WHEEL ALIGNMENT (See page SA–4) 40. PERFORM ROAD TEST Check for abnormal noise and smooth shifting. AX2–45 AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM SHIFT LOCK SYSTEM COMPONENT PARTS LOCATION WIRING DIAGRAM AX2–46 AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM ELECTRIC CONTROL COMPONENTS INSPECTION 1. INSPECT SHIFT LOCK CONTROL ECU Using a voltmeter, measure the voltage at each termi– nal. HINT: Do not disconnect the computer connector. Connector Terminal Measuring condition Voltage (V) Ignition switch ACC position Ignition switch ON position Depress brake pedal Ignition switch ACC position and P position Ignition switch ACC position and except P position (Approx–after one second) Ignition switch ON position and P position Depress brake pedal (Approx–after 20 seconds) Except P position Ignition switch ON, P position and depress brake pedal Shift except P position under conditions above Ignition switch ACC position and P position Shift except P position under condition above 2. INSPECT SHIFT LOCK SOLENOID (a) Disconnect the solenoid connector. (b) Using an ohmmeter, measure the resistance between terminals. Standard resistance: 21–27
(c) Apply the battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid. AX2–47 AUTOMATIC TRANSAXLE – SHIFT LOCK SYSTEM 3. INSPECT KEY INTERLOCK SOLENOID (a) Disconnect the solenoid connector. (b) Using an ohmmeter, measure the resistance between terminals. Standard resistance: 12.5–16–60 (c) Apply the battery positive voltage between terminals. Check that an operation noise can be heard from the solenoid. 4. INSPECT SHIFT LOCK CONTROL SWITCH Inspect that there is continuity between each termi– nal. Terminal Shift Position P position (Release button is not pushed) P position (Release button is pushed) R, N, D, 2, L position AX2–48 AUTOMATIC TRANSAXLE –Memo– – SHIFT LOCK SYSTEM AX2–49 AUTOMATIC TRANSAXLE – TROUBLESHOOTING TROUBLESHOOTING AX2–50 AUTOMATIC TRANSAXLE – TROUBLESHOOTING HOW TO PROCEED WITH TROUBLESHOOTING The Transaxle Control System broadly consists of the sensors, ECM and actuators. The ECM receives signals from various sensors, judges the operating conditions and determines the shift and lock–up timing. When troubleshooting OBD n vehicles, use an OBD II Scan Tool complying with SAE J 1978 or TOYOTA hand–held tester to confirm the diagnostic trouble codes, freezed frame data and engine data. This will enable you to determine the system causing the problem. This section explains the best method of troubleshooting and how to carry out the necessary repairs. (1) CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in as much detail as possible about the problem. (2) CONNECT THE OBDII SCAN TOOL OR TOYOTA HAND–HELD TESTER TO DLC3 Connect the OBD ll scan tool complying with SAE J 1978 or TOYOTA hand–held tester to the vehicle’s data link connector 3. NOTICE: For OBDll scan tool or TOYOTA hand–held tester operating instructions, see the instruction booklet accompanying the scan tool. If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have you have connected the scan tool/TOYOTA hand–held tester cable to DLC3, turned the ignition switch ON and operated the scan tool/TOYOTA hand–held tester, inspect DLC3 (See page AX2–57). (3) CHECK DIAGNOSTIC TROUBLE CODE AND FREEZED FRAME DATA (PRECHECK) First check the diagnostic trouble codes. If a code is output, make a note of it. Also check and note the freezed frame data. HINT: Output of the malfunction code indicates a circuit malfunction. However, it does not indicate whether the malfunction is still occurring or occurred in the past and returned to normal. To determine this, first confirm the problem symptoms in (7) and then recheck the diagnostic trouble code in¿¿. If troubleshooting has begun based only on the malfunction code in the diagnostic trouble code check in 0, it could result in a misdiagnosis and troubleshooting of circuits which are normal, making it more difficult to locate the cause of the problem. (4) CLEAR DIAGNOSTIC TROUBLE CODE AND FREEZED FRAME DATA Use the OBDII scan tool or TOYOTA hand – held tester to erase the diagnostic trouble codes and freezed frame data. NOTICE: For OBDII scan tool or TOYOTA hand–held tester operating instructions, see the instruction booklet accompanying the scan tool. (5) VISUAL INSPECTION (6) SETTING THE CHECK MODE DIAGNOSIS (7) PROBLEM SYMPTOM CONFIRMATION Confirm the problem symptoms. (8) SYMPTOM SIMULATION If the problem does not reappear, be sure to simulate the problem by mainly checking the circuits indicated by the diagnostic trouble code in step (3), using ”Problem Simulation method”. (9) DIAGNOSTIC TROUBLE CODE CHECK Check the diagnostic trouble codes. Check if there is abnormality in the sensors or the wire harness. If a malfunction code is output, proceed to (9) Diagnostic Trouble Code Chart”. If the normal code is output, proceed to (14) Matrix Chart of Problem Symptoms”. Be sure to proceed to (9) Diagnostic Trouble Code Chart” after the steps (2) to (6) inclusive are AX2–51 AUTOMATIC TRANSAXLE – TROUBLESHOOTING completed. If troubleshooting is attempted only by following the malfunction code stored in the memory is output, errors could be made in the diagnosis. DIAGNOSTIC TROUBLE CODE CHART If a trouble code is confirmed in the diagnostic trouble code check, proceed to the inspection procedure indicated by the matrix chart for each diagnostic trouble code. PRELIMINARY CHECK Carry out a preliminary check of the transmission oil level, throttle cable adjustment, etc.. MECHANICAL SYSTEM TEST (Stall Test, Time Leg Test, Line Pressure Test) If the malfunction is found in the stall test, time lag test or line pressure test, check the parts indicated in the respective tests. MANUAL SHIFTING TEST If the results of the manual driving test are NG, it is likely that the trouble is in the mechanical system or hydraulic system. Proceed to Part 2 (Mechanical System) under the Matrix Chart of Problem Symptoms. MATRIX CHART OF PROBLEM SYMPTOMS If the normal code is confirmed in the diagnostic trouble code check, perform inspection according to the inspection order in the matrix chart of problem symptoms. Perform diagnosis of each circuit or part in the order shown in the Matrix Chart. The Matrix Chart contains 3 chapters, Electronically Controlled Circuits in Chapter 1, On–vehicle Inspection in Chapter 2 and Off– vehicle Inspection in Chapter 3. If all the circuits indicated in Chapter 1 are normal, proceed to Chapter 2. If all the parts indicated in Chapter 2 are normal, proceed to Chapter 3. If all the circuits and parts in Chapter 1 – Chapter 3 are normal and the trouble still occurs, check and replace the ECM. CIRCUIT INSPECTION Perform diagnosis of each circuit in accordance with the inspection order confirmed in (9) and (13). Judge whether the cause of the problem is in the sensor, actuators, wire harness and connectors, or the ECM. In some cases, the Flow Chart instructs that a throttle signal check or brake signal check be performed. These are diagnosis functions used to check if signals are being input correctly to the ECM. PARTS INSPECTION Check the individual parts of the mechanical system and hydraulic system in the order of the numbers indicated in the Matrix Chart. REPAIRS After the cause of the problem is located, perform repairs by following the inspection and replacement procedures in this manual or’94 A541 E Automatic Transaxle Repair Manual.(for’94 CAM RY) CONFIRMATION TEST After completing adjustment or repairs, confirm not only that the malfunction is eliminated, but also conduct a test drive, etc., to make sure the entire Engine Control System is operating normally. AX2–52 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Items inside are titles of pages, in this man– ual, with the page number indicated in the bot– tom portion. See the indicated pages for detailed explanations. Vehicle Brought to Workshop Customer Problem Analysis P. AX2–53 Diagnostic steps permitting the use of the TOYOTA hand–held tester or TOYOTA brake–out–box. Connect the OBD II Scan Tool or TOYOTA Hand–Held Tester to DLC3 If your display shows “UNABLE TO CONNECT TO VEHICLE” when you hvae connected the scan tool/TOYOTA hand–held tester, inspect DLC3 P.AX2–57 Check Diagnostic Code and Freezed Frame Data (Precheck) Record or Print DTC and Freezed Frame Data P.AX2–55 Clear Diagnostic Code and Freezed Frame Data P.AX2–58 Visual Inspection Setting the Check Mode Diagnosis P. AX2–56 Symptom does not occur Problem Symptom Confirmation P. AX2–64 Symptom Simulation P. AX2–58 Symptom occurs OK Code Diagnostic Code Check NG Preliminary Check P. AX2–55 P. AX2–68 OK Mechanical System Tests NG Diagnostic Code Chart P. AX2–62 NG P. AX2–71 OK Manual Shifting Test NG P. AX2–77 OK Matrix Chart of Problem Symptoms P. AX2–81 Chapter 1 (Electronic) P. AX2–81 OK Chapter 2 (On–Vehicle) P. AX2–82 OK Chapter 3 (OFF–Vehicle) P. AX2–84 13. Circuit Inspection • Main Throttle Signal Check • Stop Light Signal Check NG Parts Inspection P. AX2–92 15. Identification of Problem Repair Confirmation Test END AX2–53 AUTOMATIC TRANSAXLE – TROUBLESHOOTING CUSTOMER PROBLEM ANALYSIS CHECK SHEET Electronically Controlled Transaxle Check Sheet Inspector’s Name : Registration No. Customer’s Name Registration Year Frame No. Date Vehicle Brouht In Odometer Reading km Miles AX2–54 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSIS SYSTEM DESCRIPTION When troubleshooting OBDII vehicles, the only dif– ference from the usual troubleshooting procedure is that you connect to the vehicle the OBDII scan tool complying with SAE J1978 or TOYOTA hand–held tester, and read off various data output from the vehicle’s ECM. OBD ll regulations require that the vehicle’s on – board computer lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the com– puter detects a malfunction in the computer itself or in drive system components which affect vehicle emi– ssions. As in previous models, when the ECM detects a malfunction in the transaxle control section, the MIL lights up and the O/D OFF indicator light blinks. In addition to the MIL lighting up when a malfunction is detected, the applicable diagnostic trouble codes pre– scribed by SAE J 2012 are recorded in the ECM memory. (See page EG–404) If the malfunction only occurs in 3 trips, the MIL goes off but the diagnostic trouble codes remain recorded in the ECM memory. The O/D OFF indicator light goes off as soon as the trouble is no longer detected. To check the diagnostic trouble codes, connect the OBDII scan tool or TOYOTA hand–held tester to Data Link Connector 3 on the vehicle. The OBD ll scan tool or TOYOTA hand–held tester also enables you to erase the diagnostic trouble codes and check freezed frame data and various forms of engine data. (For operating instructions, see the OBD III scan tool’s instruction book.) Diagnostic trouble codes include SAE controlled codes and Manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while Manufacturer controlled codes can be set freely by the manufacturer within the prescribed limits. (See diagnostic trouble code chart on page AX2–62) AX2–55 AUTOMATIC TRANSAXLE – TROUBLESHOOTING The diagnosis system operates in normal mode during normal vehicle use, and also has a check mode for technicians to simulate malfunction symptoms and perform troubleshooting. Most diagnostic trouble codes use 2 trip detection logic(‘) to prevent errone– ous detection. By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up and 0/D OFF indicator lights to blink for a malfunction that is only detected once or mo– mentarily. (TOYOTA hand–held tester) (See page AX2–56) ’ 2 trip detection logic: When a logic malfunction is first detected, the mal– function is temporarily stored in the ECM memory. If the same malfunction is detected again during the second test drive, this second detection causes the MIL to light up and O/D OFF indicator lights to blink. DIAGNOSIS INSPECTION (NORMAL MODE) MALFUNCTION INDICATOR LAMP CHECK 1. The malfunction indicator lamp comes on when the ignition switch is turned ON and the engine is not running. HINT: If the malfunction indicator lamp does not light up, troubleshoot the combination meter (See page BE–65) 2. When the engine is started, the malfunction indicator lamp should go oft. If the lamp remains on, the diagno– sis system has detected a malfunction or abnormality in the system DIAGNOSTIC TROUBLE CODE CHECK NOTICE (TOYOTA hand–held tester only): When the diagnostic system is switched from normal mode to check node, it erases all diagnostic trouble codes and freezed frame data recorded in normal mode. So before switching modes, always check the diagnostic trouble codes and freezed frame data, and note them down. 1. Prepare the OBDII scan tool (complying with SAE J 1978) or TOYOTA hand–held tester. 2. Connect the OBDll scan tool or TOYOTA hand–held tester to data link connector 3 in the fuse box at the lower left of the instrument panel. 3. Turn the ignition switch ON and turn the OBDII scan tool or TOYOTA hand–held tester switch ON. AX2–56 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 4. Use the OBD n scan tool or TOYOTA hand–held tester to check the diagnostic trouble codes and free– zed frame data. Note them down. (For operating in– structions, see the OBD n scan tool’s instruction book.) 5. See page AX2–62 to confirm the details of the diag– nostic trouble codes. NOTICE: When simulating symptoms with an OBD ll scan tool (excluding TOYOTA hand–held tester) to check the diagnostic trouble codes, use normal mode. For codes on the diagnostic trouble code chart sub– ject to ”2 trip detection logic”, turn the ignition switch off after the symptoms have been simulated the first time. Then repeat the simulation process again. When the program has been simulated twice, the MIL lights up and the diagnostic trouble codes are recorded in the ECM. DIAGNOSIS INSPECTION (CHECK MODE) TOYOTA hand–held tester only Compared to the normal mode, the check mode has high sensing ability to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check mode. DIAGNOSTIC TROUBLE CODE CHECK 1. Initial conditions. (a) Battery positive voltage 11 V or more. (b) Throttle valve fully closed. (c) Transaxle in PARK position. (d) Air conditioning switched off. 2. Turn ignition switch off. 3. Prepare the TOYOTA hand–held tester. 4. Connect the TOYOTA hand–held tester to data link connector 3 in the fuse box at the lower left of the instrument panel. 5. Turn the ignition switch ON and switch the TOYOTA hand–held tester ON. AX2–57 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 6. Switch the TOYOTA hand – held tester normal mode check mode. (Check that the MIL flashes.) 7. Start the engine. (MIL and O/D OFF indicator light go out after the engine starts.) 8. Simulate the conditions of the malfunction descr– ibed by the customer. NOTICE: Leave the ignition switch ON until you have checked the diagnostic trouble codes, etc. 9. After simulating the malfunction conditions, use the TOYOTA hand–held tester diagnosis selector to check the diagnostic trouble codes and freezed frame data, etc. HINT: Take care not to turn the ignition switch OFF, Turning the ignition switch off switches the diagnosis system from check mode to normal mode, so all diag– nostic codes, etc. are erased. 10. After checking the diagnostic trouble code, inspect the applicable circuit. DATA LINK CONNECTOR 3 INSPECTION The vehicle’s ECM uses V.P. W. (Variable Pulse Width) for communication to comply with SAE J1850. The terminal arrangement of DLC 3 complies with SAE J 1962 and matches the V.P. W. format. Terminal No. Conn¿ection/Voltage or Resistance Bus  Line Chassis Ground
Body 1
or less Signal Ground
Body 1
or less Battery Positive
Body 1
Body 9 ~ 14 V Condition During transmission Always Always Always HINT: If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of the OBD ll scan tool or TOYOTA hand–held tester to DLC 3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. (1) If communication is normal when the tool is con– nected to another vehicle, inspect DLC 3 on the original vehicle. AX2–58 AUTOMATIC TRANSAXLE – TROUBLESHOOTING (2) If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Ser– vice Department listed in the tool’s instruction manual. AXON–M CHECK FOR INTERMITTENT PROBLEMS –TOYOTA hand–held tester only– By putting the vehicle’s EC11A in check mode, 1 trip detection logic is possible instead of 2 trip detection logic and sensitivity to detect open circuits is in– creased, This makes it easier to detect a intermittent problems. CLEAR DIAGNOSTIC TROUBLE CODES See page AX2–58 SET CHECK MODE See page AX2–56 PERFORM A SIMULATION TEST Using the symptom simulation (See page IN–24), apply vibration to and pull lightly on the wire harness, connector or terminals in the circuit indicated by the malfunction code. In this test, if the malfunction indi– cator lamp lights up, it indicates that the place where the wire harness, connector or terminals being pulled or vibrated has faulty contact. Check that point for loose connection, dirt on the terminals, poor fit or other problems and repair as necessary. HINT: After canceling out the diagnostic trouble code in memory and setting the check mode, if the malfunc– tion indicator lamp does not go off after the engine is started, check thoroughly for faulty contact, etc., then try the check again. If the malfunction indicator lamp still does not go off, check and replace the EC11A. DIAGNOSTIC TROUBLE CODE CLEARANCE The following actions will erase the diagnostic trouble codes and freezed frame data. 1. Operating the OBD ll scan tool (complying with SAE J 1978) or TOYOTA hand–held tester to erase the codes. (See the OBDII scan tool’s instruction book for operating instructions.) 2. Disconnect the battery terminal or EFI fuse. AX2–59 AUTOMATIC TRANSAXLE – TROUBLESHOOTING NOTICE: If the TOYOTA hand–held tester switches the ECM from normal mode to check mode or vice – versa, or if the ignition switch is turned from ON to ACC or OFF during check mode, the diagnostic trou– ble codes and freeted frame dada will be erased. CONNECTOR CONNECTION AND TERMINAL IN– SPECTION When checking for an open circuit or short circuit, it is important to check the connector connection and the condition of the terminals. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector, a connector terminal pulled out, etc. HINT: 1. A wire rarely breaks in the middle of it’s length. Most cases occur at the connector. In particular, carefully check the connectors of sensors and ac– tuators. 2. Faulty contact could be due to rusting of the con– nector terminals, to foreign materials entering ter– minal or a drop in the contact pressure between the male and female terminals of the connector. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. There– fore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, them the cause is considered to be in the wire harness or connec– tors. SHORT CIRCUIT: This could be due to a short circuit between the wire harness and the body ground or to a short inside the switch etc. HINT: When there is a short between the wire harness and body ground, check thoroughly whether the wire har– ness is caught in the body or is clamped properly. AX2–60 AUTOMATIC TRANSAXLE – TROUBLESHOOTING VISUAL CHECK AND CONTACT PRESSURE CHECK (a) Disconnect the connectors at both ends. (b) Check for rust or foreign material, etc. in the terminals of the connectors. (c) Check crimped portions for looseness or damage and check if the terminals are secured in the lock portion. HINT: The terminals should not come out when pulled lightly. (d) Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTICE: When testing a gold–plate female terminal, always use a gold–plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. CONNECTOR HANDLING When inserting tester probes 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 care not to deform the connector terminals. AX2–61 AUTOMATIC TRANSAXLE –MEMO– – TROUBLESHOOTING AX2–62 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE CHART If a diagnostic trouble code is displayed during the diagnostic trouble code check, check the circuit listed for that code in the table below and proceed to the page given. DTC No. Detection Item Diagnostic Trouble Code Detecting Condition Output Speed Sensor Circuit Malfunction (for Electronically Controlled Transaxle) When DTC No. P0500 is detected P0750 Shift Solenoid A Malfunction During normal driving the gear required by the ECM does not match the actual gear. (2 trip detection logic) P0753 Shift Solenoid A Electrical (Shift Solenoid Valve No.1 j Open or short in shift solenoid A circuit. P0755 Shift Solenoid B Malfunction (Shift Solenoid Valve No.2) Same as for DTC No.P0750 P0758 Shift Solenoid B Electrical (Shift Solenoid Valve No.2) Open or short in shift solenoid B circuit P0720 P0770 Shift Solenoid E Malfunction (Shift Solenoid Valve SL) Lock–up does not occur when driving in the lock–up range (normal driving at 80 km/h (50 mph). Or lock–up remains ON in the lock–up OFF range. (2 trip detection logic) P0773 Shift Solenoid E Electrical (Shift Solenoid Valve SL) Open or short in shift solenoid E circuit for 1 time. (2 trip detection logic) P1705 P1765 P1780 ”NC2” Revolution Sensor Circuit Malfunction (Direct Clutch Speed Sensor) Shift Solenoid Valve SLN Circuit (For Accumulator Back Pressure Modulation) Park/neutral Position Switch Malfunction Output of direct clutch speed sensor (NC2) is 300 rpm or less under condition a) or b) a) Vehicle speed: 32 km/h (20 mph) or more b) Park/neutral position switch: OFF (2 trip detection logic) After the engine is warmed up, the current flow to the shift solenoid valve SLN is 0.2 A or less for at least 1 second under condition a) or b) (2 trip detection logic) a) Engine speed: 500 RPM or more b) Park/neutral position switch: ON (P or N position) Two or more switches are ON simultaneously for ’N’, ’2’ and ’L’ position. (2 trip detection logic) ––––––– When driving under condition a) and b) for 30 seconds or more the park/neutral position switch is ON (N position). (2 trip detection logic) a) Vehicle speed: 44 mph (70 km/ h) or more b) Engine speed: 1,500–2,500 rpm AX2–63 AUTOMATIC TRANSAXLE – TROUBLESHOOTING –...MIL does not light up
...MIL lights up ...MIL lights up, O/D OFF indicator light blinks Trouble Area MIL Memory See page • Same as for DTC No. P0500. AX2–92 • Shift solenoid valve No.1 is stuck open or closed • Valve body is blocked up or stuck. AX2–96 • Open or short in shift solenoid valve No.1 circuit. • Shift solenoid valve No.1 • ECM AX2–98 • Shift solenoid valve No.2 is stuck open or closed • Valve body is blocked up or stuck. AX2–96 • Open or short in shift solenoid valve No.2 circuit. • Shift solenoid valve No.2 ECM AX2–98 • • • AX2–102 Shift solenoid valve SL is stuck open or closed. Lock–up clutch Valve body is blocked up or stuck. • Open or short in shift solenoid valve SL circuit. • Shift solenoid valve SL • ECM • Open or short in direct clutch speed sensor circuit. • Direct clutch speed sensor • ECM AX2–104 AX2–108 • Open or short in shift solenoid valve SLN circuit. • Shift solenoid valve SLN • ECM AX2–112 • Short in park/neutral position switch circuit. • Park/neutral position switch • ECM AX2–116 AX2–64 AUTOMATIC TRANSAXLE – TROUBLESHOOTING ROAD TEST NOTICE: Perform the test at normal ATF operating tem– perature 50–80
C (122–176
F). 1. D POSITION TEST (NORM AND PWR PATTERN) Shift into the D position and fully depress the acceler– ator pedal and check the following points: (a) Check up–shift operation.1
2, 2
3 and 3
O/D up–shift takes place, at the shift point shown in the automatic shift schedule. (See page AX2–67) HINT: (1) O/D Gear Up–shift Prohibition Control • Coolant temp. is 55
C (131
F) or less • If there is a 10 km/h (6 mph) difference between the set cruise control speed and vehicle speed. • 0/D main switch is pushed ON (During the O/D OFF indicator light lights up.) (2) O/D Gear Lock–up Prohibition Control • Brake pedal is depressed. • Coolant temp. is 55
C (131
F) or less. (b) Check for shift shock and slip. Check for shock and slip at the 1–2, 2–3 and 3–O/ D up–shifts. (c) Check for abnormal noises and vibration. Run at the D position lock–up or O/D gear and check for abnormal noises and vibration. HINT: The check for the cause of abnormal noises and vibration must be performed very thoroughly as it could also be due to loss of balance in the differential, torque converter clutch, etc.. AX2–65 AUTOMATIC TRANSAXLE – TROUBLESHOOTING (d) Check kick–down operation While running in the D position, 2nd, 3rd and 0/D gears, check to see that the possible kick–down vehicle speed limits for 2
1, 3
2 and 0/D
3 kick–downs conform to those indicated on the auto– matic shift schedule. (See page AX2–67) (e) Check abnormal shock and slip at kick–down. (f) Check the lock–up mechanism. (1) Drive in D position, O/D gear, at a steady speed (lock–up ON) of about 70 km/h (43 mph). (2) Lightly depress the accelerator pedal and check that the engine RPM does not change abruptly. If there is a big jump in engine RPM, there is no lock–up. 2. 2 POSITION TEST Shift into the 2 position and fully depress the acceler– ator pedal and check the following points: (a) Check up–shift operation. Check to see that the 1–)2 up–shift takes place and that the shift point conforms to the automatic shift schedule.(See page AX2–67) HINT: There is no 0/D up–shift and lock–up in the 2 position. (b) Check engine braking. While running in the 2 position and 2nd gear, release the accelerator pedal and check the engine braking effect. (c) Check for abnormal noises during acceleration and deceleration, and for shock at up–shift and down– shift. AX2–66 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 3. L POSITION TEST Shift into the 2 position and fully depress the acceler– ator pedal and check the following points: (a) Check no up–shift. While running in the L position, check that there is no up–shift to 2nd gear. (b) Check engine braking. While running in the L position, release the accelera– tor pedal and check the engine braking effect. (c) Check for abnormal noises during acceleration and deceleration. 4. R POSITION TEST Shift into the R position and fully depress the acceler– ator pedal and check for slipping. CAUTION: Before conducting this test ensure that the test area is free from personnel and obstruction. 5. P POSITION TEST Stop the vehicle on a gradient (more than 5
) and after shifting into the P position, release the parking brake. Then, check to see that the parking lock pawl holds the vehicle in place. AX2–67 AUTOMATIC TRANSAXLE – TROUBLESHOOTING AUTOMATIC SHIFT SCHEDULE SHIFT POINT Shift position Shifting point Vehicle speed km/h (mph) Throttle valve fully opened D position Throttle valve fully closed Throttle valve fully opened 2 position L position Throttle valve fully opened LOCK–UP POINT D position km/h (mph) Throttle valve opening 596 Lock–up ON ’3rd Gear 0/D Gear *: 0/D Switch OFF HINT: (1) There is no lock–up in the 2 and L positions. (2) In the following cases, the lock–up will be released regardless of the lock–up pattern. • When the throttle valve is completely closed. • When the brake light switch is ON. (3) Shift up to 3rd will not occur when the engine coolant temp. is below 35
C (95
F) and the vehicle speed is below 40 km/h (25 mph). (4) Shift–up to 0/D will not occur when the engine coolant temp. is below 60
C (140
F) and the vehicle speed is below 63 km/h (39 mph). (5) During cruise control operation ; the shift pattern is fixed in NORM. And when the vehicle speed drops to 10 km/h (6 mph) or more below the cruise control set vehicle speed, shift down from 0/D to 3rd occurs. (6) The kick–down foot switch turns ON when the accelerator pedal is depressed further with the throttle valve already fully open. AX2–68 AUTOMATIC TRANSAXLE – TROUBLESHOOTING PRELIMINARY CHECK 1. CHECK FLUID LEVEL HINT: • Drive the vehicle so that the engine and transmis– sion are at normal operating temperature. Fluid temp. : 70–80 C (158–176 F) • Only use the COOL position on the dipstick as a rough reference when the fluid is replaced or the engine does not run. (a) Park the vehicle on a level surface and set the parking brake. (b) With the engine idling and the brake pedal depressed, shift the shift lever into all positions from P to L position and return to P position. (c) Pull out the dipstick and wipe it clean. (d) Push it back fully into the tube. (e) Pull it out and check that the fluid level is in the HOT position. If the level is at the low side, add fluid. Fluid type: DEXRON
II or equivalent NOTICE: Do not overfill. 2. CHECK FLUID CONDITION If the fluid smells burnt or is black, replace it. 3. REPLACE TRANSAXLE FLUID (a) Remove the drain plug and drain the fluid. (b) Reinstall the drain plug securely. (c) With the engine OFF, add new fluid through the oil filler tube. Fluid type:DEXRON^II or Equivalent Capacity: Total: 6.75 liters (7.1 US qts, 5.9 Imp. qts) Drain and refill: 3.5 liters (3.7 US qts, 3.1 Imp. qts) (d) Start the engine and shift the shift lever into all posi– tions from P to L position and then shift into P posi– tion. (e) With the engine idling, check the fluid level. Add fluid up to the COOL level on the dipstick. (f) Check the fluid level at the normal operating tempera– ture, 70–80 C (158–176 *F), and add as necessary. NOTICE: Do not overfill. 4. CHECK FLUID LEAKS Check for leaks in the transmission. If there are leaks, it is necessary to repair or replace 0 –rings, seal packings, oil seals, plugs or other parts. AX2–69 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 5. INSPECT AND ADJUST THROTTLE CABLE (a) Check that the accelerator pedal is fully released. (b) Check that the inner cable is not slack. (c) Measure the distance between the outer cable end and stopper on the cable. Standard distance: 0–1 mm (0–0.04 In.) If the distance is not standard, adjust the cable by the adjusting nuts. 6. INSPECT AND ADJUST SHIFT LEVER POSITION When shifting the shift lever from the N position to other positions, check that the lever can be shifted smoothly and accurately to each position and that the position indicator correctly indicates the position. If the indicator is not aligned with the correct position, carry out the following adjustment procedures. (a) Loosen the swivel nut on the manual shift lever. (b) Push the manual lever fully toward the right side of the vehicle. (c) Return the lever 2 notches to N position. (d) Set the shift lever to N position. (e) While holding the shift lever lightly toward the R position side, tighten the swivel nut. (f) Start the engine and make sure that the vehicle moves forward when shifting the lever from the N to D position and reverses when shifting it to the R posi– tion. 7. INSPECT AND ADJUST PARK/NEUTRAL POSITION SWITCH Check that the engine can be started with the shift lever only in the N or P position, but not in other positions. If not as started above, carry out the following adjust– ment procedure. (a) Loosen the park/neutral position switch bolt and set the shift lever to the N position. (b) Align the groove and neutral basic line. (c) Hold in position and tighten the bolt. AX2–70 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) For continuity inspection of the park/neutral position switch, see page AX–116. 8. INSPECT IDLE SPEED Idle speed: 650–750 RPM (In N position and air conditioner OFF) AX2–71 AUTOMATIC TRANSAXLE – TROUBLESHOOTING MECHANICAL SYSTEM TESTS STALL TEST The object of this test is to check the overall performance of the transaxle and engine by measuring the stall speeds in the D and R positions. NOTICE: • • • • Perform the test at normal operating fluid temperature 50–80
C (122–176
F). Do not continuously run this test longer than 5 seconds. To ensure safety, conduct this test in a wide, clear, level area which provides good traction. The stall test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is performing the test. MEASURE STALL SPEED (a) Chock the four wheels. (b) Connect a tachometer to the engine. (c) Fully apply the parking brake. (d) Keep your left foot pressed firmly on the brake pedal. (e) Start the engine. (f) Shift into the D position. Press all the way down on the accelerator pedal with your right foot. Quickly read the stall speed at this time. Stall speed: 2,600 ±150 RPM (g) Perform the same test in R position. AX2–72 AUTOMATIC TRANSAXLE – TROUBLESHOOTING EVALUATION Possible cause Problem • Engine output may be insufficient. • Stator one–way clutch is operating properly (a) Stall speed low in D and R positions. (b) Stall speed high in D position. HINT: If more than 600 RPM below the specified value, the torque converter could be faulty. • • • • Line pressure too low Forward clutch slipping No.2 one–way clutch not operating properly (c) Stall speed high in R position. • • • • O/D one–way clutch not operating properly Line pressure too low Direct clutch slipping First and reverse brake slipping O/D clutch slipping (d) Stall speed high in D and R position. • • • Line pressure too low Improper fluid level O/D one–way clutch not operating properly AX2–73 AUTOMATIC TRANSAXLE – TROUBLESHOOTING TIME LAG TEST When the shift lever is shifted while the engine is idling, there will be a certain time lapse or lag before the shock can be felt. This is used for checking the condition of the 0/D direct clutch, forward clutch, direct clutch, and first and reverse brake. NOTICE: • Perform the test at normal operating fluid temperature 50–80
C (122–176
F). • Be sure to allow a one minute interval between tests. • Make three measurements and take the average value. MEASURE TIME LAG (a) Fully apply the parking brake . (b) Start the engine and check idle speed. Idle speed: 650–750 RPM (In N position and air conditioner OFF) (c) Shift the shift lever from N to D position. Using a stop watch, measure the time it takes from shifting the lever until the shock is felt. In same manner, measure the time lag for N  R. Time lag: N  D Less than 1.2 seconds N  R Less than 1.5 seconds AX2–74 AUTOMATIC TRANSAXLE – TROUBLESHOOTING EVALUATION If N
D or N
R time lag are longer than specified: Possible cause Problem ND time lag is longer NR time lag is longer • • • • • • • Line pressure too low Forward clutch worn 0/D one–way clutch not operating properly Line pressure too low Direct clutch worn First and reverse brake worn O/D one–way clutch not operating properly AX2–75 AUTOMATIC TRANSAXLE – TROUBLESHOOTING MEASURE LINE PRESSURE NOTICE: • • Perform the test at normal operating fluid temperature 50–80
C (122–176
F). The line pressure test should always be carried out in pairs. One technician should observe the conditions of wheels or wheel stoppers outside the vehicle while the other is performing the test. • Be careful to prevent the oil pressure gauge hose from interfering with the exhaust pipe. (a) Warm up the transmission fluid. (b) Remove the test plug on the transaxle case left side and connect the oil pressure gauge SST. SST 09992–00094 (c) Fully apply the parking brake and chock the four wheels. (d) Start the engine and check idling RPM. (e) Keep your left foot pressed firmly on the brake pedal and shift into D position. (f) Measure the line pressure when the engine is idling. (g) Press the accelerator pedal all the way down. Quickly read the highest line pressure when engine speed reaches stall speed. (h) In the same manner, perform the test in R position. AX2–76 AUTOMATIC TRANSAXLE – TROUBLESHOOTING SPECIFIED LINE PRESSURE Condition D position kPa (kgf/cm2, psi) R position kPa (kgf/cm2, psi) Idling Stall If the measured pressures are not up to specified values, recheck the throttle cable adjustment and retest. EVALUATION Problem If the measured values at all positions are higher. If the measured values at all positions are lower. If pressure is low in the D position only. If pressure is low in the R position only. Possible cause • • • • • • • • • • • • • Throttle cable out of adjustment Throttle valve defective Regulator valve defective Throttle cable out of adjustment Throttle valve defective Regulator valve defective Oil pump defective 0/D direct clutch defective D position circuit fluid leakage Forward clutch defective R position circuit fluid leakage Direct clutch defective First and reverse brake defective AX2–77 AUTOMATIC TRANSAXLE – TROUBLESHOOTING MANUAL SHIFTING TEST HINT: With this test, it can be determined whether the trouble is within the electrical circuit or is a mechani– cal problem in the transaxle. 1. DISCONNECT SOLENOID WIRE 2. INSPECT MANUAL DRIVING OPERATION Check that the shift and gear positions correspond with the table below. Shift Position Gear Position D Position O/D 2 Position 3rd L Position R Position Reverse P Position Pawl Lock HINT: If the L, 2 and D position gear positions are difficult to distinguish, perform the following road test. • While driving, shift through the L, 2 and D positions. Check that the gear change corresponds to the shift position. If any abnormality is found in the above test, the problem is in the transmission itself. 3. CONNECT SOLENOID WIRE 4. CANCEL OUT DIAGNOSTIC TROUBLE CODE (See page AX2–58) AX2–78 AUTOMATIC TRANSAXLE – TROUBLESHOOTING STANDARD VALUE OF ECM TERMINAL ECM Terminals E9 Connector,Terminal No. Symbols Wiring Color E10 Condition Standard Value 1. Disconnect cruise control connector. 2. Turn ignition switch ON. Standing still Turn one front wheel slowly IG OFF IG ON 1 st or 2nd gear 3rd or O/D gear IG OFF IG ON 2nd or 3rd gear 1 st or O/D gear IG OFF IG ON Vehicle driving under lock–up position IG OFF Engine is running IG switch ON IG switch ON 0/D main switch ON O/D main switch OFF IG switch ON Pattern select switch ’NORM’ Pattern select switch ’PWR’ AX2–79 AUTOMATIC TRANSAXLE – TROUBLESHOOTING IG switch ON Shift lever L position Shift lever other than L position 1G switch ON Shift lever 2 position Shift lever other than 2 position IG switch ON Shift lever R position Shift lever other than R position IG switch ON Shift lever P or N position Shift lever other than P and N position IG switch ON Brake pedal is depressed Brake pedal is released AX2–80 AUTOMATIC TRANSAXLE – TROUBLESHOOTING MATRIX CHART OF PROBLEM SYMPTOMS If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs, check the circuits for each symptom in the order given in the charts on the following pages and proceed to the page given for troubleshooting. The Matrix Chart is divided into 3 chapters. Chapter 1: Electronic Circuit Matrix Chart Chapter 2: On–vehicle Repair Matrix Chart Chapter 3: Off–vehicle Repair Matrix Chart When troubleshooting, check Chapter 1 first. If instructions are given in Chapter 1 to proceed to Chapter 2 or 3, proceed as instructed. 1. If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow chart for each circuit, proceed to the circuit with the next highest number in the table to continue the check. 2. If the trouble still occurs even though there are no abnormalities in any of the other circuits, then check or replace the ECM. AX2–81 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Vehicle does not move in any forward range and reverse range Vehicle does not move in particular range or ranges 1st
2nd No up–shift 2nd
3rd 3rd
O/D O/D
3rd No down–shift 3rd
2nd 2nd
1st No lockup No lockup off Shift point too high or too low Upshifts is to 2nd while in L range Upshifts to 3rd while in L range Upshifts to O/D from 3rd while O/D switch is OFF Upshifts to O/D from 3rd while engine is cold N
D Harsh engagement Lockup Any driving range Forward and reverse Slip or Shudder Particular range No engine Braking Poor acceleration No kickdown No pattern select Large shift shock or Engine stalls when starting off or stopping. AX2–84 Of–Vehicle repair matrix chart AX2–82 On–Vehicle repair matrix chart AX2–128 Stop Light Switch Circuit AX2–116 Park/Neutral Position Switch Circuit AX2–122 AX2–126 Pattern Select Switch Circuit Symptom OD Cansel Signal Circuit Suspect Area 0/D Main Switch & O/D OFF Indicator Light Circuit See Page AX2–120 Chapter 1. Electronic Circuit AX2–82 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Chapter 2. On–Vehicle Repair (* : A541 E AUTOMATIC TRANSAXLE Repair Manual) Vehicle does not move in R position Vehicle does not move in any forward position or reverse position No lock–up No lock–up OFF No kick–down No engine braking 2nd 1st2nd No up–shift 2nd  3rd 3rdO/D O/D 3rd No down–shift 3rd 2nd 2nd
1 st NR ND N L 1 st2nd (D position) 1 st2nd (2 Position) Harsh engagement 1st2nd3rd 1st2nd 3rdO/D 2nd3rd 3rdO/D O/D3rd 3rd2nd Sliper shudder in forward and reverse (Directly after E/G start) Low coast modulator valve 2nd coast modulator valve Secondary regulator valve Cut–Back valve Down–shift plug Throttle valve Symptom Primary regulator valve Suspect Area Manual valve See page OFF–Vehicle repair AX2–84 matrix chart Oil strainer Parking lock pawl Pressure relief valve B2accumulator Bo accumulator C2 accumulator – C1 a cumulator Co accumulator Solenoid modulator valve Accumulator control valve 3–4 shift valve 2–3 shift valve 1–2 shift valve Lock–up relay valve, B1 Orifice control valve 2nd lock valve AUTOMATIC TRANSAXLE TROUBLESHOOTING AX2–83 AX2–84 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Chapter 3. Off–Vehicle Repair ( * : A541 E AUTOMATIC TRANSAXLE Repair Manual) Vehicle does not move in any forward position Vehicle does not move in reverse position Vehicle does not move in any forward position and reverse position No lock–up No lock–up OFF Large shock during lock–up E/G stalls when starting off and stopping 1 st2nd No up–shift 2nd3rd 3rdO/D No down shift 2nd
1 st NR Harsh engagement Slip on shudder ND 1 st2nd (D position) 2nd3rd 3rdO/D Forward and reverse (After warm–up) Forward and reverse (Directly after E/G start) R position 1 st 2nd 2nd3rd (Up–shift) 3rd O/D 1 st
3rd No engine braking Poor acceleration 2nd A11 positions O/D Other than O/D Other than 2nd 1 st and 2nd 1 st and R position R position O/D brake (Bo) Direct Clutch (C2) Forward clutch (C1 ) O/D direct clutch (CO) Symptom Parking lock pawl Suspect Area Torque converter clutch See page – Rear planetary gear Front planetary gear O/D planetary gear No.2 one–way clutch IF21 No. 1 one–way clutch (F i ) O/D one–way clutch (FD) 1 st and reverse brake (B3) Second brake (621 2nd coast brake (B, ) AUTOMATIC TRANSAXLE TROUBLESHOOTING AX2–85 AX2–86 AUTOMATIC TRANSAXLE – TROUBLESHOOTING LOCATION OF CONNECTORS Location of Connectors in Engine Compartment Data Link Connector 1 Electronic Controlled Transaxle Connector Junction Connector EF 1 Park/neutral Position SW O/D Direct Clutch Speed Sensor AX2–87 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Location of Connectors in Body Sedan Light Failure Sensor AX2–88 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Location of Connectors in Instrument Panel Combination Meter E6 Electronic Controlled Transaxle Pattern Select Switch C11 Combination Meter Engine Control Module C16 Cruise Control ECU Engine Control Module AX2–89 AUTOMATIC TRANSAXLE Engine Control Module Noise Filter Noise Filter Junction Connector – TROUBLESHOOTING E10 Engine Control Module 112 Ignition SW and Unlock Warning SW S10 Stop Light Switch O/D Main SW Junction Connector Junction Connector 112 IP3 Ia1 1P1 AX2–90 AUTOMATIC TRANSAXLE J/B No.1 – TROUBLESHOOTING AX2–91 AUTOMATIC TRANSAXLE J/B No.2 J/B No–3 – TROUBLESHOOTING AX2–92 AUTOMATIC TRANSAXLE – TROUBLESHOOTING CIRCUIT INSPECTION DTC P0720 Output Speed Sensor Circuit Malfunction (For Electronically Controlled Transaxle) CIRCUIT DESCRIPTION The vehicle speed sensor outputs a 4–pulse signal for every revolution of the transaxle differential. After this signal has been converted into a more precise rectangular wave form by the wave form shaping circuit inside the combination meter, it is then transmitted to the ECM. Transaxle DTC No. P0720 Diagnostic Trouble Code Detecting Condition When DTC No. P0500 is detected Trouble Area • Same as for DTC No. P0500 < Reference > • Waveform between terminals SP 1 and E l when vehicle speed is approx. 20 km/h (12 MPH). HINT: The greater the vehicle speed, the greater the number of VSS signals produced. AX2–93 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC CHART Measure voltage between terminals SP 1 and E, of ECM connector. Go to step Measure voltage between terminal 14 of combination meter center connector and body ground. Check for open circuit between ECM and combination meter. Check combination meter. Check continuity between terminal SP1 of ECM connector and body ground. Replace ECM. WIRING DIAGRAM Check for short circuit between ECM, cruise control ECU and com– bination meter. AX2–94 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Measure voltage between terminals SP 1 and E 1 of ECM connector. 1. Disconnect cruise control ECU connector. 2. Turn IG switch ON. Measure voltage between terminals SP1 and E1 of ECM connector. Voltage: 5 V Go to step Measure voltage between terminal 14 of combination meter center connector and body ground. 1. Remove the combination meter, but do not disconnect the connectors. 2. Turn 1 G switch ON. Measure voltage between terminal 4 of combina– tion meter connector and body ground. Voltage: 5 V Check for open circuit between ECM and combination meter. Check combination meter. AX2–95 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check continuity between terminal SP1 of ECM connector and body ground. Disconnect connector from ECU. Check continuity between terminal SP1 of ECM connector and body ground. No continuity Check for short circuit between ECM, cruise control ECU and combination meter. Replace ECM. AX2–96 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DTC P0750 Shift Solenoid A Malfunction Shift Solenoid No.1 DTC P0755 Shift Solenoid B Malfunction Shift Solenoid No.2 SYSTEM DESCRIPTION The ECM uses signals from the NC2 revolution sensor and vehicle speed sensor to detect the actual gear position(1 st, 2nd, 3rd or O/D gear). Then the ECM compares the actual gear with the shift schedule in the ECM memory to detect mechanical trouble of the shift solenoid valves and valve body. DTC No. P0750 P0755 Diagnostic Trouble Code Detecting Condition During normal driving the gear required by the ECM does not match the actual gear. (2 trip detection logic) Trouble Area • Shift solenoid valve No.1lNo.2 is stuck open or closed. • Valve body is blocked up or stuck. Check the No. 1 solenoid when diagnostic trouble code P0750 is output and check No.2 solenoid when diagnostic trouble code P0755 is output DIAGNOSTIC CHART Check solenoid valve No. 1 or No. 2 opera– tion. Replace No. 1 or No. 2 solenoid valve. Check valve body (See page AX2–82). Repair or replace valve body. Repair or replace transaxle (See page AX2–27). AX2–97 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check solenoid valve No. 1 or No.2 operation. 1. Remove the oil pan. 2. Remove the No. 1 or No. 2 solenoid valve. 1. Applying 490 kPa (5 kg/flcm2, 71 psi) of com– pressed air, check that the solenoid valves do not leak the air. 2. When battery voltage is supplied to the solenoid valves, check that the solenoid valves open. Replace No. 1 or No.2 solenoid valve. Check valve body (See page AX2–82). Repair or replace valve body. Repair or replace transaxle (See page AX2–27). AX2–98 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DTC P0753 Shift Solenoid A Electrical Malfunction (Shift Solenoid Valve No. 7) DTC P0758 Shift Solenoid B Electrical Malfunction (Shift Solenoid Valve No. 2) CIRCUIT DESCRIPTION The ECM controls the shifting from 1st to O/D in combination with ON and OFF of the shift solenoid valves No. 1 and No. 2. If an open or short circuit occurs in either of the shift solenoid valves, the ECM controls the remaining normal shift solenoid valve to allow the vehicle to be operated smoothly (Fail safe function). Fail Safe Function If either of the shift solenoid valve circuits develops an open or a short, the ECM turns the other shift solenoid ON and OFF to shift to the gear positions shown in the table below. The ECM also turns the shift solenoid valve SL OFF at the same time. If both solenoids malfunction, hydraulic control cannot be perform– ed electronically and must be done manually. Manual shifting as shown in the following table must be done. (in the case of a short circuit, the ECM stops sending current to the short circuited solenoid). NO. 1 SOLENOID MALFUNCTIONING NORMAL Position Solenoid valve No. 1 No. 2 OFF Gear Solenoid valve No. 1 No.2 1 st 2nd OFF OFF OFF OFF OFF OFF 3rd O/D OFF NO.2 SOLENOID MALFUNCTIONING Gear Solenoid valve No. 1 No. 2 BOTH SOLENOIDS MALFUNCTIONING Gear Gear when shift selector is manually operated 3rd 1 st O/D 3rd OFF O/D O/D 3rd O/D OFF O/D O/D OFF O/D O/D 1 st 3rd 1 st O/D 2nd 3rd OFF O/D O/D 3rd 1 st OFF O/D O/D 3rd 1 st 2nd OFF 1 st 1 st 2nd 1 st x; Malfunctions Check the shift solenoid valve No. 1 when diagnostic trouble code P0753 is output and check the shift solenoid valve No.2 when diagnostic trouble code P0758 is output. DTC No. P0753 P0758 Diagnostic Trouble Code Detecting Condition Short or open in shift solenoid valve No. 1 l No. 2 circuit. Trouble Area • • • Shift solenoid valve No. 1 INo.2 circuit. Shift solenoid valve No. 1lNo.2. ECM AX2–99 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC CHART Measure resistance between S 1 or S2 ter– minal of ECM connector and body ground. Check harness and connector between ECM and automatic transaxle solenoid connector. Inspect No.1 or No.2 solenoid valve. Repair or replace solenoid wire. WIRING DIAGRAM Replace ECM. Repair or replace harness or con– nector. Replace malfunctioned solenoid valve. AX2–100 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Measure resistance between S 1 or S2 terminals of ECM connector and body ground. Measure resistance between S 1 or S2 terminals of ECM connector and body ground. Resistance: 10–16 9 Replace ECM. Check harness and connector between ECM and automatic transaxle solenoid connector. Disconnect the solenoid connector on the automatic transaxle. Check harness and connector between S 1 and S2 terminals of ECM connector and 3 terminals of solenoid connector. There is no open and no short circuit. Repair or replace harness or connector. AX2–101 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check No. 1 or No.2 solenoid valves. 1. Jack up the vehicle. 2. Remove oil pan. 3. Disconnect solenoid connector. 4. Remove No. 1 or No. 2 solenoid valve. Measure resistance between solenoid connector and body ground. Resistance: 10–16 Ω Connect positive
lead to terminal of solenoid connector, negative lead to solenoid body The solenoid makes an operating noise. Replace solenoid valve. Repair or replace solenoid wire. AX2–102 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DTC P0770 Shift Solenoid E Malfunction (Shift Solenoid Valve SL) SYSTEM DESCRIPTION The ECM uses the signals from the NC2 revolution sensor and crankshaft position sensor to monitor the engagement condition of the lock–up clutch. Then the ECM compares the engagement condition of the lock–up clutch with the lock–up schedule in the ECM memory to detect mechanical trouble of the shift solenoid valve SL, valve body and torque converter. DTC No. P0770 Diagnostic Trouble Code Detecting Condition Lock–up does not occur when driving in the lock– up range (normal driving at 50mph [80kmlh]. Or lock–up remains ON in the lock–up OFF range. (2 trip detection logic) Trouble Area • Shift solenoid valve SL is stuck open or closed. • • Valve body, blocked up or stuck. Lock–up clutch. DIAGNOSTIC CHART Check solenoid valve SL operation. Replace solenoid valve SL. Check valve body (See page AX2–82). Repair or replace valve body. Replace torque converter clutch (See page AX2–27). AX2–103 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check solenoid valve SL operation. Remove SL solenoid valve from valve body. 1. Applying 490 kPa (5 kgf/cm2, 71 psi)of com– pressed air, check that the solenoid valves do not leak air. 2. When battery voltage is supplied to the solenoid valves, check that the solenoid valves open. Replace solenoid valve SL. Check valve body (See page AX2–82). Repair or replace valve body. Replace torque converter clutch. AX2–104 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DTC P0773 Shift Solenoid E Electrical Malfunction (Shift Solenoid Valve SL) CIRCUIT DESCRIPTION The shift solenoid valve SL is turned ON and OFF by signals from the ECM to control the hydraulic pressure acting on the lock–up relay valve, which then controls operation of the lock–up clutch. Fail Safe Function If the ECM detects a malfunction, it turns the shift solenoid valve SL OFF. DTC No. P0773 Diagnostic Trouble Code Detecting Condition Open or short in shift solenoid SL circuit for 1 time. (2 trip detection logic) • • • Trouble Area Open or short in shift solenoid valve SL cir– cuit. Shift solenoid valve SL. ECM AX2–105 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC CHART Measure resistance between terminals SL and E, of ECM connector. Replace ECM. Check harness and connector between ECM and automatic transaxle. Repair or replace harness or con– nector between ECM and automatic transaxle solenoid connector. Check SL solenoid valve. Replace SL solenoid valve. Check and replace or repair the solenoid wire. WIRING DIAGRAM AX2–106 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Measure resistance between terminals SL of ECM connector and body ground. Disconnect connector from the ECM. Measure resistance between terminals SL and E, of the ECM. Resistance: 8–100,000
Replace ECM. Check harness and connector between ECM and automatic transaxle. 1. Disconnect the connector from the ECM. 2. Disconnect the solenoid connector from the transaxle. Check harness between terminal SL of the ECM connector and terminal 3 of automatic transaxle solenoid connector. There is no open or short circuit. Repair or replace harness or connector bet ween ECM connector and automatic transaxle solenoid connector. AX2–107 AUTOMATIC TRANSAXLE – TROUBLESHOOTING 1. 2. 3. 4. Jack–up the vehicle. Remove oil pan. Disconnect SL solenoid valve connector. Remove SL solenoid valve. Check SL solenoid valve. Measure resistance between SL solenoid connec– tor terminal and its body ground. Resistance: 10–16 9 Check SL solenoid valve operation noise when applying battery voltage to the solenoid connec– tor terminal and it’s body. The SL solenoid valve makes operation noise. Replace SL solenoid valve. Check and replace or repair the solenoid wire. AX2–108 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DTC Pl705 “NC2” Revolution Sensor Circuit Malfunction (Direct Clutch Speed Sensor) CIRCUIT DESCRIPTION This sensor detects the rotation speed of the direct clutch drum. By comparing the direct clutch speed signal and the vehicle speed sensor signal, the ECM detects the shift timing of the gears and ap– propriately controls the engine torque and hydraulic pressure in response to various conditions, thus performing smooth gear shif– ting. DTC No. P1705 Diagnostic Trouble Code Detecting Condition Out put of direct clutch speed sensor (NC2) is 300 rpm or less under condition a) and b). a) Vehicle speed: 32 km/h (20 mph) or more b) Park/neutral position switch: OFF (2 trip detection logic) Trouble Area • Open or short in direct clutch speed sen– sor circuit. • Direct clutch speed sensor. • ECM AX2–109 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC CHART Check resistance between terminals NC2+ and NC2–of ECM connector. Replace ECM. Check direct clutch speed sensor. Replace direct clutch speed sen– sor. Check and repair harness and connector between ECM and O/D direct clutch speed sensor. WIRING DIAGRAM AX2–110 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check resistance between terminals NC2+ and NC2–of ECM connector. Check resistance between terminals NC2+ and NC2–of ECM connector. Resistance: 560–680 9 Replace ECM. Check direct clutch speed sensor. Remove direct clutch speed sensor. (See page AX2–1 5) Measure resistance between terminals 1 and 2 of speed sensor. Resistance: 560–680

Reference  Check the speed sensor’s function Check voltage between terminals 1 and 2 of the speed sensor when a magnet is put close to the front end of the speed sensor then taken away quickly. Voltage is generated intermittently. The voltages generated is extremely low. Replace direct clutch speed sensor. Check and repair harness and connector between ECM and direct clutch speed sensor. AX2–111 AUTOMATIC TRANSAXLE –MEMO– – TROUBLESHOOTING AX2–112 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DTC P1765 Shift Solenoid Valve SLN Circuit (For Accumulator Back Pressure Modulation) CIRCUIT DESCRIPTION The shift solenoid valve SLN controls the hydraulic pressure acting on the accumulator control valve when gears are shifted and per– forms smooth gear shifting. The ECM determines optimum operating pressure according to the signals from the throttle position sensor, vehicle speed sensor and direct clutch speed sensor and controls the volume of current flow to the solenoid valve. The amount of current to the solenoid is controlled by the (*) duty ratio of ECM output signals, causing a momentary change to the hydraulic pressure acting on the clutches during gear shifting. When the duty ratio is high, the hydraulic pressure acting on the clutches is low. (*) Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non–continuity, then Duty Ratio = A X 100% A+B DTC No. P1765 Diagnostic Trouble Code Detecting Condition After the engine is warmed up, the current flow to the shift solenoid valve SLN is 0.2A or less for at least 1 sec. under condition ay or b). (2 trip detection logic) aj Engine speed: 500 rpm or more b) Park/neutral position switch: ON (P or N position) < Reference > • Waveform between terminals SLN– and E 1 when engine is idling. Trouble Area • Open or short in shift solenoid valve SLN circuit. • Shift solenoid valve SLN. • ECM • Waveform between terminals SLN– and E 1 during shift change. AX2–113 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DIAGNOSTIC CHART Check solenoid valve SLN. Check harness and connector between bat– tery and solenoid valve SLN, solenoid valve SLN and ECM (See page IN–31 ). Replace ECM. WIRING DIAGRAM Replace solenoid valve SLN. Repair or replace harness or con– nector. AX2–114 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check shift solenoid valve SLN. Check solenoid resistance 1. Jack up the vehicle. 2. Remove oil pan. 3. Disconnect the connector. Measure resistance between terminals 1 and 2 of solenoid connector. Resistance: 5.1–5.5 9 Check solenoid operation Connect positive
lead with an 8–10 w bulb to terminal 1 of solenoid connector and negative lead to terminal 2, then check the movement of the valve. When battery voltage is applied. Valve moves in mm1 direction in illustration. (on the left) When battery voltage is cut off. Valve moves in direction in illustration. (on the right) < Reference > Check solenoid operation 1. Prepare a variable power supply. 2. Connect positive
lead of the variable power supply to terminal 1 of solenoid connector and negative 0 lead to terminal 2. 3. Check the movement of the valve when the voltage is gradually increased. (A current greater than 1 A should not be supplied.) As the voltage is increased, the valve should move slowly in the direction. 4. Check the movement of the valve when the voltage is cut off. The valve should return in the Replace solenoid valve SLN. direction. AX2–115 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check harness and connector between battery and shift solenoid valve SLN, shift solenoid valve SLN and ECM (See page IN–31). Repair or replace harness or connector. Replace ECM. AX2–116 AUTOMATIC TRANSAXLE – TROUBLESHOOTING DTC P1780 Park Neutral Position Switch Malfunction CIRCUIT DESCRIPTION The park/neutral position switch detects the shift lever position and sends signals to ECM. The ECM receives signals (R, NSW, 2 and L) from the park/neutral position switch. When the signal is not sent to the ECM from the park/neutral position switch, the ECM judges that the shift lever is in the D posi– tion. DTC No. Diagnostic Trouble Code Detecting Condition Trouble Area Two or more switches are ON simultaneously for ”N”, ”2” and ”L” position. (2 trip detection logic) P 1780 When driving under conditions a) and b) for 30 seconds or more, the park/neutral position switch is ON (N position). (2 trip detection logic) a) Vehicle speed: 44 mph (70 km/h) or more b) Engine speed: 1,500–2,500 rpm • Short in park/neutral position switch circuit • Park/neutral position switch • ECM DIAGNOSTIC CHART Check voltage between terminal R, NSW, 2, L of ECM connector and body ground. Proceed to next circuit inspection shown on matrix chart (See page AX2–8 1 ). Check PNP switch. Replace PNP switch. Check harness and connector between ECM and PNP switch, PNP switch and bat– tery. Check and replace ECM. Repair or replace harness or con– nector. AX2–117 AUTOMATIC TRANSAXLE WIRING DIAGRAM – TROUBLESHOOTING AX2–118 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminal R, NSW, 2, L of ECM connector and body ground. Turn ignition switch ON. Measure voltage between terminals R, NSW, 2, L of ECM connector and body ground when the shift lever is shifted to the following positions. Position R–body ground NSW–body 2–body ground ground L–body ground P, N 10–14V* 10–14V* 10–14V 10–14V 10–14V 10–14 V 10–14V *: The voltage will drop slightly due to lighting up of the back up light. Proceed to next circuit inspection shown on matrix chart (See page AX2–81 ). Check PNP switch. Remove PNP switch (See page AX2–16). Check continuity between each terminal shown below when the shift lever is shifted to each posi– tion. Continuity Terminal Shift Position Replace PNP switch. AX2–119 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check harness and connector between ECM and PNP switch, PNP switch and battery. Repair or replace harness and connector. Check and replace ECM. AX2–120 AUTOMATIC TRANSAXLE – TROUBLESHOOTING OD Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruis– ing, overdrive may be prohibited temporarily in some conditions. The cruise control ECU sends O/D cut signals to the ECM as necessary and the ECM cancels overdrive shif– ting until these signals are discontinued. DIAGNOSTIC CHART Check voltage between terminal OD 1 of ECM connector and body ground. Proceed to next circuit inspection shown on matrix chart (See Page AX2–81). Check voltage between terminal OD of cruise control ECU harness side connector and body ground. Check and replace cruise control ECU. Check harness and connector between cruise control ECU and ECM. Check and replace ECM. WIRING DIAGRAM Repair or replace harness or con– nector. AX2–121 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminal OD 1 of ECM connector and body ground. Turn ignition switch ON. Measure voltage between terminal OD 1 of ECM connector and body ground. Voltage: 4–6 V Proceed to next circuit inspection shown on matrix chart (See page AX2–81). Check voltage between terminal OD of cruise control ECU harness side connector and body ground. 1. Disconnect cruise control ECU connector. 2. Turn ignition switch ON. Measure voltage between terminal OD of cruise control ECU harness side connector and body ground. Voltage: 4–6 V Check and replace cruise control ECU. Check harness or connector between cruise control ECU and ECM. Repair or replace harness or connector. Check and replace ECM. AX2–122 AUTOMATIC TRANSAXLE – TROUBLESHOOTING OD Main Switch & OD OFF Indicator Light Circuit CIRCUIT DESCRIPTION The O/D main switch contacts go off when the switch is pushed in and come on when it is pushed out. In O/D main switch OFF position, the O/D OFF indicator lights up, and the ECM prohibits shifting to overdrive. The ECM also causes the O/D OFF indicator light to blink when a malfunction is detected. In this case, con– necting the OBD II scan tool or TOYOTA hand–held tester to the DLC3 can display the diagnostic trouble code. DIAGNOSTIC CHART O/D OFF indicator light does not light up. Check operation of O/D main switch. Check voltage between terminal OD2 of ECM connector and body ground. Check. harness and connector between O/D off indicator light and ECM. Go to step Proceed to next circuit inspection shown on matrix chart (See page AX–81 ). Repair or replace harness or con– nector. Check and replace ECM. Check O/D main switch. Check and replace combination meter. (See combination meter troubleshooting) Replace O/D main switch. AX2–123 AUTOMATIC TRANSAXLE – TROUBLESHOOTING O/D OFF indicator light remains ON Check O/D main switch. Replace O/D main switch. Check harness and connector between O/D off indicator light and O/D main switch, O/D off indicator light and ECM. Repair or replace harness or con– nector. Check and replace ECM. O/D OFF indicator light blinks Perform diagnostic code check (See page AX2–55). WIRING DIAGRAM ( * ) O/D Main Switch Contacts go off with switch pushed in. Contacts go on with switch pushed out. AX2–124 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check operation of O/D Main Switch. 1. Turn ignition switch ON 2. Check ”O/D OFF” light when O/D main switch is pushed in to ON. “O/D OFF” light goes off. 3. Check ”O/D OFF” light when O/D main switch is pushed again, to OFF. “O/D OFF” light lights up. If the–O/D OFF” lights blinks when the O/D main switch is pushed in to ON, a malfunction is occurr– ing in the system. Check the diagnostic trouble code. Go to step Check voltage between terminal OD2 of ECM connector and body ground. Turn ignition switch ON. Check voltage between terminal OD2 of ECM and body ground. O/D Main Switch OFF Voltage Below 1 V 10 ^–14 V Proceed to next circuit inspection shown on matrix chart (See page AX2–81). AX2–125 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Check harness and connector between O/D off indicator light and ECM. Repair or replace harness or connector. Check and replace ECM. Check O/D Main Switch. 1. Disconnect O/D main switch connector. 2. Measure resistance between terminals 1 and 3 of O/D main switch connector. O/D Main Switch Resistance ^ 9 (open) OFF 0 S2 (continuity) Replace O/D Main Switch. Check and replace combination meter. (See com– bination meter troubleshooting.) AX2–126 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Pattern Select Switch Circuit CIRCUIT DESCRIPTION The ECM memory contains the shift programs for the NORMAL and POWER patterns, 2 position, and L position and the lockup patterns. Following the programs corresponding to the signals from the pattern select switch, the park/neutral position switch and other various sensors the ECM switches the solenoid valves ON and OFF, thereby controlling the transaxle gear change and the lockup clutch operation. DIAGNOSTIC CHART Check voltage between terminal P of ECM connector and body ground. Proceed to next circuit inspection shown on matrix chart (See page AX2–81 ) . Check pattern select switch. Replace pattern select switch. Check harness and connector between ECM and pattern select switch, pattern select switch and battery (See page IN–31 ). Check and replace ECM. WIRING DIAGRAM Repair or replace harness or con– nector. AX2–127 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check voltage between terminal P of ECM connector and body ground. Turn ignition switch ON. Measure voltage between terminal P of ECM con– nector and body ground when the pattern select switch is set to the PWR (POWER) position and NORM (NORMAL) position. Voltage Pattern select switch 10–14 V PW R Below 1 V NORM The ECU uses the normal pattern signal if the power signal is not input. Proceed to next circuit inspection shown on matrix chart (See page AX2–81). Check pattern select switch. Disconnect pattern select switch connector. (See BO–section) Measure resistance between terminals 3 and 6 of pattern select switch connector when the select switch is set to PWR and NORM positions. Pattern Resistance PWR 0 Q (continuity) NORM ^ 0 (open) Replace pattern select switch. Check harness and connector between ECM and pattern select switch, pattern select switch, pattern select switch and battery (See page IN–31). Repair or replace harness or connector. Check and replace ECM. AX2–128 AUTOMATIC TRANSAXLE – TROUBLESHOOTING Stop Light Switch Circuit CIRCUIT DESCRIPTION The purpose of this circuit is to prevent the engine from stalling, while driving in lockup condition, when brakes are suddenly applied. When the brake pedal is operated, this switch sends a signal to ECM. Then the ECM cancels operation of the lockup clutch while braking is in progress. DIAGNOSTIC CHART Check operation of stop light. Check and repair stop light circuit. Connect the TOYOTA hand–held tester and check STP signal. Proceed to next circuit inspection shown on matrix chart (See page AX2–8 1 ). Check harness and connector between ECM and stop light switch. Repair or replace harness or con– nector. Check and replace ECM. AX2–129 AUTOMATIC TRANSAXLE WIRING DIAGRAM – TROUBLESHOOTING AX2–130 AUTOMATIC TRANSAXLE – TROUBLESHOOTING INSPECTION PROCEDURE Check operation of stop light. Check if the stop lights go on and off normally when the brake pedal is operated and released. Check and repair stop light circuit. Connect TOYOTA hand–held tester and check STP signal. 1. Remove the fuse cover on the instrument panel. 2. Connect the TOYOTA hand–held tester to the DLC 3 (OBD II connector). 3. Turn ignition switch ON and TOYOTA hand– held tester main switch ON. Read the STP signal on the TOYOTA hand–held tester. Brake pedal is depressed: STP ON Brake pedal is released: STP OFF Proceed to next circuit inspection shown on matrix chart (See page AX2–81). Check harness and connector between ECM and stop light switch. Repair or replace harness or connector. Check and replace ECM. AX2–131 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA Line pressure (whell locked) Engine idling D position R position AT stall D position R position Engine stall revolution N position–D position N position–R position Time lag Engine idle speed (Cooling fan and A/C OFF) N position Throttle cable adjustment (Throttle valve fully opened) Torque converter clutch runout Drive plate runout Limit Limit SHIFT POINT Shift position Shifting point Vehicle speed km/h (mph) Throttle valve fully opened D position Throttle valve fully closed Throttle valve fully opened 2 position L position Throttle valve fully opened LOCK–UP POINT D position km/h (mph) Throttle valve opening 596 3rd Gear (O/D switch OFF) O/D Gear Lock–up ON Lock–up OFF AX2–132 AUTOMATIC TRANSAXLE – SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS Part tightened N–m Engine front mounting bracket x Front suspention menber Engine rear mounting bracket x Front suspention menber LH transaxle mounting Transaxle x Engine 12mm bolt Transaxle x Engine 10mm bolt Torque converter clutch x Drive–plate Valve body x Transaxle case Oil strainer Oil pan Oil pan drain plug Park/Neutral position switch x Transaxle case (bolt) Park/Neutral position switch (nut) B, apply tube retainer Manual valve body Detent spring Oil tube bracket Steering gear housing x Front suspention Menber Stabilizer bar bracket Vehicle speed sensor Direct clutch speed sensor Transfer lubulication apply tube retainer Exhaust manifold plate Front frame x Body 19 mm Front frame x Body 12 mm Front frame x Body Nut Exhaust front pipe x Exhaust tale pipet Exhaust manifold x Exhaust front pipe Exhaust pipe clamp Starter Throttle cable adjusting nut kgf–cm ft–lbf BE–1 BODY ELECTRICAL SYSTEM – BODY ELECTRICAL SYSTEM BE–2 BODY ELECTRICAL SYSTEM – GENERAL INFORMATION GENERAL INFORMATION WIRING COLOR CODE Wire colors are indicated by an alphabetical code. B=Black L=Blue R=Red BR=Brown LG=Light Green V =Violet G=Green O=Orange W=White GR=Gray P=Pink Y =Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. CONNECTOR 1. PIN NUMBER OF FEMALE CONNECTOR Numbered in order from upper left to lower right. 2. PIN NUMBER OF MALE CONNECTOR Numbered in order from upper right to lower left. HINT: When connectors with different of the same number of terminals are used with the same parts, each connector name (letter of the alphabet) and pin number is specified. 3. DISTINCTION OF MALE AND FEMALE CONNEC– TORS Male and female connectors are distinguished by shape of their internal pins. (a) All connectors are –shown from the open end, and the lock is on top. (b) To pull apart the connectors, pull on the connector itself, not the wires. HINT: Check to see what kind of connector you are disconnecting before pulling apart. BE–3 BODY ELECTRICAL SYSTEM – GENERAL INFORMATION HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER (a) Locking device must be disengaged before the termi– nal locking clip can be released and the terminal re– moved from the connector. (b) Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTICE: Do not remove the terminal retainer from con– nector body. (c) Release the locking lug from terminal and pull the terminal out from rear. 4. INSTALL TERMINAL TO CONNECTOR (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. (b) Push the secondary locking device or terminal retainer in to the full lock position. 5. CONNECT CONNECTOR BE–4 BODY ELECTRICAL SYSTEM – GENERAL INFORMATION FUSE REPLACEMENT HINT: If replacing the fuse be sure to replace it with a fuse with an equal amperage rating. NOTICE: • Turn off all electrical components and the ignition switch before replacing a fuse or fusible link. Do not exceed the fuse or fusible link amperage rating. • Always use a fuse puller for removing and inserting a fuse. Remove and insert straight in and out with– out twisting. Twisting could force open the termi– nals too much, resulting in a bad connection. If a fuse or fusible link continues to blow, a short circuit is indicated. The system must be checked by a qualified technician. HINT: The puller is located at Junction Block No.2. BE–5 BODY ELECTRICAL SYSTEM – GENERAL INFORMATION VOLTAGE CHECK (a) Establish conditions in which voltage is present at the check point. Example: A–Ignition SW on B–Ignition SW and SW 1 on C–Ignition SW, SW 1 and Relay on (SW 2 off) (b) Using a voltmeter, connect the negative (–) lead to a good ground point or negative (–) battery terminal and the positive (+) lead to the connector or compo– nent terminal. This check can be done with a test bulb instead of a voltmeter. CONTINUITY AND RESISTANCE CHECK (a) Disconnect the battery terminal or wire so there is no voltage between the check points. (b) Contact the 2 leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the 2 leads and check again. When contacting the negative (–) lead to the diode positive (+) side and the positive (+) lead to the negative (–) side, there should be continuity. When contacting the 2 leads in reverse, there should be no continuity. HINT: Specifications may vary depending on the type of tester, so refer to the tester’s instruction manual before performing the inspection. Check LED (Light Emitting Diode) in the same manner as that for diodes. HINT: • Use a tester with a power source of 3 V or greater to overcome the circuit resistance. • If a suitable tester is not available, apply battery positive voltage and check that the LED lights up. BE–6 BODY ELECTRICAL SYSTEM – GENERAL INFORMATION (c) Use a volt/ohmmeter with high impedance (10 k/V minimum) for troubleshooting of the electrical circuit. BULB CHECKING (a) Remove the bulb. (b) There should be continuity between the respective terminals of the bulb together with a certain amount of resistance. (c) Apply the 2 leads of the ohmmeter to each of the terminals. (d) Apply battery positive voltage and check that the bulb lights up. SHORT CIRCUIT CHECK (a) Remove the blown fuse and eliminate all loads from the fuse. (b) Connect a test bulb in place of the fuse. (c) Establish conditions in which the test bulb comes on. Example: A–Ignition SW on B–Ignition SW and SW 1 on C–Ignition SW, SW 1 and Relay on (Connect the Relay) and SW 2 off (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while wat– ching the test bulb. The short lies between the con– nector where the test bulb stays lit and the connector where the bulb goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. BE–7 BODY ELECTRICAL SYSTEM – PRECAUTION PRECAUTION Take care to observe the following precautions when performing inspections or remOval and replacement of body electrical related parts. HEADLIGHT SYSTEM • Halogen bulbs have pressurized gas inside and require special handling. They can burst or scatter if scratched or dropped. Hold a bulb only by its plastic or metal case. Don’t touch the glass part of a bulb with bare hands. SRS (SUPPLEMENTAL RESTRAINT SYSTEM) • Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. • When disconnecting any of the connectors in the SRS, be sure to lock the ignition switch and disconnect the negative (–) terminal cable from the battery first. Since the connectors are twin lock type connectors, disconnect the connectors only after releasing the first stage lock. • When connecting SRS connectors, be sure to lock them securely. (If the connectors are not locked securely, the system may not operate when needed.) • Always store the steering wheel pad with the pad surface facing upward. (Storing the pad with its metallic surface up may lead to a serious accident if the air bag inflates for some reason.) • When installing the spiral cable, be sure the vehicle is in the straight ahead condition and confirm that the spiral cable is in the neutral position when it is installed. (See page BE–28) • INFORMATION LABELS (NOTICE) are attached to the periphery of the air bag components. Follow the NOTICE. AUDIO SYSTEM • If the negative (–) terminal cable is disconnected from the battery, the preset AM, FM 1 and FM 2 stations stored in memory are erased, so be sure to note the stations and reset them after the battery terminal is reconnected. • If the negative (–) terminal cable is disconnected from the battery, the ”ANTI–THEFT SYSTEM” will operate when the cable is reconnected, but the radio, tape player and CD player will not operate. Be sure to input the correct ID number so that the radio, tape player and CD player can be operated again. MOBILE COMMUNICATION SYSTEM • If the vehicle is equipped with a mobile communication system, refer to precautions in the IN section. BE–8 BODY ELECTRICAL SYSTEM – PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) 09213–31021 Crankshaft Pulley Puller For removing steering wheel RECOMMENDED TOOLS 09062–00050 TOYOTA Electrical Tester Set 09041–00030 Torx Driver T30 For removing and installing steering wheel pad 09042–00010 Torx Socket T30 For removing and installing steering wheel pad EQUIPMENT Voltmeter Ammeter Ohmmeter Test lead Syphon Bulb (3.4 W) Brake fluid level warning switch Bulb (21 W) Turn signal flasher relay Dry cell battery Fuel sender gauge Fuel sender gauge, Seat belt warning relay Torque wrench Masking tape Rear window defogger wire Tin foil Rear window defogger wire BE–9 BODY ELECTRICAL SYSTEM – POWER SOURCE POWER SOURCE PARTS LOCATION BE–10 BODY ELECTRICAL SYSTEM – POWER SOURCE Junction Block No.2 MEDIUM CURRENT FUSES 1. MAIN 40A 2. RDI 30A 3. CDS 30A FUSES 4. – 5. EFI 15A 15A 6. HORN 10A 10A 7. OBD, TRAC 7.5A 7.5A 8. HAZ 1 OA 10A 20A 9. DOME 20A 15A 10. H–LP LH 15A 15A 11. H–LP RH 15A 7.5A 12. ALT 7.5A 30A 13. AMZ 30A 15A 14. ECU–B 15A SHORT 15. D.C. C. SHORT RELAYS A. EFI Relay B. Starter Relay C. HORN Relay D. HEAD (Headlight Control) Relay E. ENG MAI N. FR–DEF Relay F. FAN Relay Junction Block No. 1 (Rear Side) A. Noise Filter MEDIUM CURRENT FUSES a. AM 1 40A b. POWER 30A c. DEFOG 40A FUSES 1. ECU–IG 15A 15A 2. GAUGE 10A 10A 15A 3. STOP 15A 20A 4. 7.5A 5. WIPER 20A 7.5A 6. TURN 7.5A 15A 7. 1G2 7.5A 10A 8. CIGI RADIO 15A 15A 9. MIR HTR 10A 15A 10. TAIL 15A 11. ECU–S 15A 12. – RELAY B. Integration Relay BE–11 BODY ELECTRICAL SYSTEM – POWER SOURCE Junction Block No. 1 (Front Side) RELAYS A. Power Main Relay B. Taillight Control Relay C. Defogger Relay Relay Block No–1 FUSE 1. ST Fuse 10A RELAY A. Turn Signal Flasher Relay Block No.4 FUSES Medium Current Fuse 1. HEATER 40A Fuse 2. A/C 1 OA RELAY A. Heater Relay BE–12 BODY ELECTRICAL SYSTEM – POWER SOURCE Relay Block No.5 • 5S–FE Engine FUSES 1. HEAD RH (Lo) 15A (CANADA) 2. HEAD LH (Lo) 15A (CANADA) RELAYS A. Daytime Running Light Relay No.2 (CANADA) B. Magnet Clutch Relay C. FAN No.2 Relay D. FAN No.3 Relay • 1 MZ–FE Engine Relay Block No.6 FUSES 1. ––– 2. ––– 3. HEAD RH (Lo) 15A (CANADA) 4. HEAD LH (Lo) 15A (CANADA) RELAYS A. Daytime Running Light Relay No.2 (CANADA) 6. Magnet Clutch Relay C. Fuse Pump Relay RELAY A. Circuit Opening Relay Relay Block No.7 (CANADA) FUSE 1. DRL 7.5A RELAYS A. DRL No.4 Relay B. DRL No.3 Relay BE–13 BODY ELECTRICAL SYSTEM – POWER SOURCE WIRING DIAGRAM BE–14 BODY ELECTRICAL SYSTEM – IGNITION SWITCH IGNITION SWITCH PARTS LOCATION IGNITION SWITCH INSPECTION INSPECT IGNITION SWITCH Continuity Inspect the switch continuity between terminals. Switch position Tester connection to terminal number LOCK ACC START Specified value No continuity 3–4 Continuity 2–3–4 9–10 Continuity 2–4–7 6–9–10 Continuity If continuity is not as specified, replace the switch. BE–15 BODY ELECTRICAL SYSTEM – KEY UNLOCK WARNING SYSTEM KEY UNLOCK WARNING SYSTEM PARTS LOCATION KEY UNLOCK WARNING SWITCH INSPECTION INSPECT KEY UNLOCK WARNING SWITCH Continuity Inspect the switch continuity between terminals. Condition Tester connection to terminal number Switch OFF (Key removed) Switch ON (Key set) Specified value No continuity 1–5 Continuity If continuity is not as specified, replace the switch. BE–16 BODY ELECTRICAL SYSTEM – KEY UNLOCK WARNING SYSTEM INTEGRATION RELAY INSPECTION INSPECT INTEGRATION RELAY Relay Circuit/ Key Unlock Warning System Remove the relay from the junction block No.1 and inspect the connectors on the junction block side. Tester connection to terminal number Condition Specified value (Continuity) A5 – Ground Key unlock warning switch OFF No continuity A5 – Ground Key unlock warning switch ON Continuity A6 – Ground Driver’s door courtesy switch OFF No continuity A6 – Ground Driver’s door courtesy switch ON Continuity A 10 – Ground Constant Continuity Tester connection to terminal number A1 – Ground Condition Specified value (Voltage) Battery positive voltage A7 – Ground Constant Ignition switch position LOCK or ACC No voltage A7 – Ground Ignition switch position ON Battery positive voltage If circuit is as specified, trying replacing the relay with a new one. Is circuit is not as specified, inspect the circuits con– nected to other parts. DOOR COURTESY SWITCH See page BE–43. BE–17 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT AND TAILLIGHT SYSTEM PARTS LOCATION BE–18 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM BE–19 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty. HEADLIGHT (USA) Trouble Parts name Headlight does not light. (Taillight is normal) 1. MAIN FL 2. Wire Harness 3. HEAD–(LH, RH) Fuse 4. Headlight Bulb Headlight does not light. (Taillight does not light up) 1. MAIN FL 2. Wire Harness 3. Headlight Control Relay 4. HEAD–(LH, RH) Fuse 5. Headlight Bulb Only one side light does not light. 1. HEAD–(LH, RH) Fuse 2. Headlight Bulb 3. Wire Harness ”Lo– Beam” does not light. 1. Wire Harness 2. Headlight Bulb 3. Light Control Switch ”Hi–Beam” does not light. ’Flash” does not light. ”Auto Turn –off System” dose not operate. (See page) (BE–4) (BE–30) (BE–4) (BE–4) (BE–29) 1. Headlight Dimmer Switch 2. Wire Harness 3. Light Control Switch (BE–29) 1. Headlight Dimmer Switch 2. Wire Harness (BE–29) 1. Integration Relay 2. GAUGE Fuse 3. Ignition Switch 4. Door Courtesy Switch (Driver’s) 5. Wire Harness 6. DOME Fuse (BE–31) (BE–4) (BE–14) (BE–43) (BE–29) (BE–4) BE–20 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM TAILLIGHT (USA) Trouble Parts name (See page) Taillight does not light. (Headlight does not light) 1. Light Control Switch 2. Integration Relay 3. Wire Harness (BE–29) (BE–31) Taillight does not light. (Headlight is normal) 1. TAIL Fuse 2. Taillight Control Relay 3. Light Control Switch 4. Integration Relay 5. Wire Harness (BE–4) (BE–30) (BE–29) (BE–31) Only one side light does not light. 1. Bulb 2. Wire Harness Rear Combination light does not light. 1. Wire Harness 2. Light Failure Sensor 3. Bulb ”Auto Turn–Off System” dose not operate. 1. Integration Relay 2. Wire Harness 3. GAUGE Fuse 4. Door Courtesy Switch (Driver’s) (BE–73) (BE–31) (BE–4) (BE–43) BE–21 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT (CANADA) Trouble Parts name (See page) Headlight does not light. (Taillight is normal) 1. Wire Harness Headlight does not light. (Taillight does not light up) 1. MAIN FL 2. Wire Harness (BE–4) Only one side light does not light. 1. HEAD LO (LH, RH) Fuse 2. Headlight Bulb 3. Wire Harness 1. Headlight Control Relay 2. Light Control Switch 3. Integration Relay 4. Wire Harness 5. HEAD LO (LH, RH) Fuse 6. Headlight Bulb (BE–30) (BE–29) (BE–31) ”Lo–Beam” does not light. ’Hi–Beam’ does not light. ”Flash” does n6t light. ’Auto Turn–off System’ does not operate. 1. DRL Fuse 2. Daytime Running Light Relay No.2 3. Daytime Running Light Relay (Main) 4. Daytime Running Light Relay No.3 5. Daytime Running Light Relay No.4 6. ECU – B Fuse 7. Headlight Dimmer Switch 8. Wire Harness 9. HEAD HI (LH, RH) Fuse 10. Headlight Bulb 1. DRL Fuse 2. Daytime Running Light Relay No.2 3. Daytime Running Light Relay (Main) 4. Daytime Running Light Relay No.3 5. Daytime Running Light Relay No.4 6. ECU – B Fuse 7. Headlight Dimmer Switch 8. Wire Harness 9. HEAD HI (LH, RH) Fuse 10. Headlight Bulb 1. Integration Relay 2. GAUGE Fuse 3. Ignition Switch 4. Door Courtesy Switch (Drivers) 5. Wire Harness 6. DOME Fuse (BE–4) (BE–4) (BE–33) (BE–32) (BE–33) (BE–34) (BE–4) (BE–29) (BE–4) (BE–4) (BE–33) (BE–32) (BE–33) (BE–34) (BE–4) (BE–29) (BE–4) (BE–31) (BE–4) (BE–14) (BE–43) (BE–4) Headlight does not light with engine running and light control SW in OFF. *Terminal L of Generator and Parking Brake Switch 1. GAUGE Fuse 2. ECU – B Fuse 3’. Other Parts 4. Daytime Running Light Relay (Main) 5. Wire Harness 6. HEAD HI (LH, RH) Fuse 7. Headlight Bulb (BE–4) (BE–4) (BE–32) (BE–4) BE–22 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM TAILLIGHT (CANADA) Trouble Parts name (See page) Taillight does not light. (Headlight does not light) 1. Light Control Switch 2. Integration Relay 3. Wire Harness (BE–29) (BE–31) Taillight does not light. (Headlight is normal) 1. TAIL Fuse 2. Taillight Control Relay 3. Light Control Switch 4. Integration Relay 5. Wire Harness (BE–4) (BE–30) (BE–29) (BE–31) Only one side light does not light. 1. Bulb 2. Wire Harness Rear Combination light does not light. 1. Wire Harness 2. Light Failure Sensor 3. Bulb ”Auto Turn–Off System” does not operate. 1. Integration Relay 2. GAUGE Fuse 3. Wire Harness 4. Door Courtesy Switch (Driver’s) *1: Terminal L of Generator and Parking Brake Switch (BE–73) (BE–31) (BE–4) (BE–43) BE–23 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT AIM ADJUSTMENT COMBINATION SWITCH REMOVAL See page BO–108. BE–24 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM COMBINATION SWITCH DISASSEMBLY Components BE–25 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM 1. REMOVE WIRE HARNESS HOLDER NO.1 2. REMOVE TERMINALS FROM CONNECTOR (a) Release the 4 tabs and open the terminal cover. NOTICE: Do not remove terminal for SRS connector (Yellow). (b) From the open end, insert a miniature screwdriver between the locking lug and terminal. (c) Pry down the locking lug with the screwdriver and pull the terminal out from the rear. 3. REMOVE WIRE HARNESS HOLDER NO. 2 (a) Remove the clamp. (b) Pry loose 2 locking lugs. (c) Remove the 2 screws and the wire harness holder No. 2. 4. REMOVE SPIRAL CABLE SUBASSEMBLY (a) Disconnect the connector. (b) Remove the 4 screws and the spiral cable sub– assembly. BE–26 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM 5. REMOVE WIRE HARNESS CLAMP Remove the screw and the wire harness clamp. 6. REMOVE LIGHT CONTROL AND FOG LIGHT SWITCH (a) Remove the 2 screws and the ball set plate from the switch body. (b) Remove the ball and side out the switch from the switch body with the spring. 7. REMOVE HEADLIGHT DIMMER AND TURN SIGNAL SWITCH Remove the 4 screws and the headlight dimmer and turn signal switch from the switch body. 8. REMOVE WIPER AND WASHER SWITCH Remove the 2 screws and the wiper and washer switch from the switch body. BE–27 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM COMBINATION SWITCH ASSEMBLY INSTALL PARTS OF COMBINATION SWITCH IN RE– VERSE SEQUENCE OF DISASSEMBLY (MAIN POINT OF ASSEMBLY) 1. INSTALL LIGHT CONTROL SWITCH (a) Slide the switch and install the switch body. (b) Set the lever in the HI position, and install the ball and plate. (c) After installing the light control switch to the switch body, insure that the switch operation is smooth. 2. INSTALL TERMINALS TO CONNECTOR • Push in the terminal until it is securely locked in the connector lug. • Install each switch terminal, as shown in the figure. BE–28 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM COMBINATION SWITCH INSTALLATION For installation, follow the removal procedure in re– verse. (MAIN POINT OF INSTALLATION) ADJUSTMENT OF SPIRAL CABLE (a) Check that the front wheels are facing straight ahead. (b) Turn the spiral cable counterclockwise by hand until it becomes harder to turn the cable. (c) Then rotate the spiral cable clockwise about 3 turns to align the red mark. HINT: • The spiral cable will rotate about 3 turns to either left or right of the center. • The connector should be straight up. (d) Install the steering wheel so that the match marks will not be misaligned. BE–29 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM COMBINATION SWITCH INSPECTION 1. INSPECT LIGHT CONTROL SWITCH Continuity Inspect the switch continuity between terminals. Switch position Tester connection to terminal number OFF TAIL HEAD Specified value No continuity A2 – All A2 –All –A13 Continuity Continuity If continuity is not as specified, replace the switch. 2. INSPECT DIMMER SWITCH Continuity Inspect the switch continuity between terminals. Switch position Flash Low beam High beam Tester connection to terminal number Specified value A9–A12–A14 Continuity A3 – A9 A9 – A12 Continuity Continuity If continuity is not as specified, replace the switch. 3. INSPECT TURN SIGNAL SWITCH Continuity Inspect the switch continuity between terminals. Switch position Tester connection to terminal number Left turn A 1 – A5 Neutral Right turn Specified value Continuity No continuity A 1 – A8 Continuity If continuity is not as specified, replace the switch. BE–30 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM HEADLIGHT CONTROL RELAY INSPECTION INSPECT HEADLIGHT CONTROL RELAY Continuity Inspect the relay continuity between terminals. Condition Constant Apply B + between terminals 1 and 2. Tester connection to terminal number Specified value 1–2 Continuity 3–4 Continuity If continuity is not as specified, replace the relay. TAILLIGHT CONTROL RELAY INSPECTION INSPECT TAILLIGHT CONTROL RELAY Continuity Inspect the relay continuity between terminals. Condition Constant Apply B + between terminals 1 and 2. Tester connection to terminal number Specified value 1–2 Continuity 3–5 Continuity If continuity is not as specified, replace the relay. LIGHT FAILURE SENSOR See page BE–73. BE–31 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM INTEGRATION RELAY INSPECTION INSPECT INTEGRATION RELAY Relay Circuit/ Light Auto Turn Off System Remove the relay from junction block and inspect the connectors on the wire harness and junction block side, as shown in the chart. Tester connection to terminal number Condition Driver’s door courtesy switch OFF Specified value (Continuity) No continuity Driver’s door courtesy switch ON Continuity Constant Light control switch position OFF Continuity Light control switch position TAIL and HEAD No continuity Continuity Light control switch position OFF or TAIL No continuity Light control switch position HEAD Continuity Condition Specified value (Voltage) Constant Battery positive voltage Ignition switch position LOCK or ACC No voltage Ignition switch position ON Battery positive voltage Constant Battery positive voltage Constant Battery positive voltage If the circuit is as specified, trying replacing the relay with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. BE–32 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM DAYTIME RUNNING LIGHT RELAY (MAIN) INSPECTION (for CANADA) INSPECT DAYTIME RUNNING LIGHT RELAY (MAIN) Circuit/ Wire Harness Side Disconnect the connector from relay and inspect the connector on wire harness side, as shown. Tester connection to terminal number Condition Specified value (Continuity) Light control switch position OFF or TAIL No continuity Light control switch position HEAD Continuity Headlight dimmer switch position Low beam No continuity or high beam Headlight dimmer switch position Flash Continuity Parking brake switch position OFF No continuity Parking brake switch position ON Continuity Constant Continuity Headlight dimmer switch position Low beam No continuity Headlight dimmer switch position Flash or High beam Condition Continuity Specified value (Voltage) Ignition switch position LOCK or ACC No voltage Ignition switch position ON or START Battery positive voltage Constant Battery positive voltage Engine Stop No voltage Engine Running Battery positive voltage If circuit is as specified, perform the inspection on the following page. If circuit is not as specified, inspect the circuits con– nected to other parts. BE–33 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM DAYTIME RUNNING LIGHT RELAY NO.2 INSPECTION (for CANADA) INSPECT DAYTIME RUNNING LIGHT RELAY NO.2 Continuity Inspect the relay continuity between terminals. Condition Constant Apply B + between terminals 2 and 4. Tester connection to terminal number Specified value 1–4 2–4 Continuity 3–4 Continuity If continuity is not as specified, replace the relay. DAYTIME RUNNING LIGHT RELAY NO–3 INSPECTION (for CANADA) INSPECT DAYTIME RUNNING LIGHT RELAY NO–3 Continuity Inspect the relay continuity between terminals. Condition Constant Apply B + between terminals 1 and 3. Tester connection to terminal number Specified value 1–3 2–4 Continuity 4–5 Continuity If continuity is not as specified, replace the relay. BE–34 BODY ELECTRICAL SYSTEM – HEADLIGHT AND TAILLIGHT SYSTEM DAYTIME RUNNING LIGHT RELAY NO.4 INSPECTION INSPECT DAYTIME RUNNING LIGHT RELAY NO.4 Continuity Condition Constant Apply B + between terminals 1 and 2. Tester connection to terminal number Specified value 1–2 Continuity 3–4 Continuity If continuity is not as specified, replace the relay. DOOR COURTESY SWITCH See page BE–43. PARKING BRAKE SWITCH See page BE–72. IGNITION SWITCH See page BE–14. BE–35 BODY ELECTRICAL SYSTEM – TURN SIGNAL AND HAZARD WARNING SYSTEM TURN SIGNAL AND HAZARD WARNING SYSTEM PARTS LOCATION BE–36 BODY ELECTRICAL SYSTEM – TURN SIGNAL AND HAZARD WARNING SYSTEM BE–37 BODY ELECTRICAL SYSTEM – TURN SIGNAL AND HAZARD WARNING SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty. Trouble Parts name (See page) ’Hazard’ and ”Turn” do not light up. 1. Hazard Warning Switch 2. Turn Signal Flasher 3. Wire Harness The flashing frequency is abnormal. 1. Bulb 2. Turn Signal Switch 3. Wire Harness Hazard warning light does not light up. (Turn is normal) 1. HAZ–HORN Fuse 2. Wire Harness (BE–4) Hazard warning light does not light up in one direction. 1. Hazard Warning Switch Z. Wire Harness (BE–38) *1 Turn signal does not light up. 1. Ignition Switch 2. TURN Fuse 3. Turn Signal Switch 4. Wire Harness (BE–14) (BE–4) (BE–38) *2 Turn signal does not light up. 1. TURN Fuse 2. Turn Signal Switch 3. Wire Harness (BE–4) (BE–38) Turn signal does not light up in one direction. 1. Turn Signal Switch 2. Wire Harness (BE–38) Only one bulb does not light up. 1. Bulb 2. Wire Harness *1: Combination Meter, Wiper and Washer do not operate. *2: Combination Meter, Wiper and Washer are normal. (BE–38) (BE–38) (BE–38) BE–38 BODY ELECTRICAL SYSTEM – TURN SIGNAL AND HAZARD WARNING SYSTEM TURN SIGNAL SWITCH See page BE–29. HAZARD WARNING SWITCH INSPECTION INSPECT HAZARD WARNING SWITCH Continuity Inspect the switch continuity between terminals. Condition Tester connection to terminal number Specified value Switch OFF 7–10 Continuity Switch ON 7–8 5–6–9 Continuity Illumination circuit 2–3 Continuity If continuity is not as specified, replace the switch. TURN SIGNAL FLASHER INSPECTION INSPECT TURN SIGNAL FLASHER Operation (a) Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 3. (b) Connect the 2 turn signal light bulbs parallel to each other to terminals 1 and 3, check that the bulbs flash. HINT: The turn signal lights should flash 60 or 120 times per minute. If one of the front or rear turn signal lights has an open circuit, the number of flashers will be more than 140 per minute. If operation is not as specified, replace the flasher. BE–39 BODY ELECTRICAL SYSTEM – INTERIOR LIGHT SYSTEM INTERIOR LIGHT SYSTEM PARTS LOCATION BE–40 BODY ELECTRICAL SYSTEM – INTERIOR LIGHT SYSTEM BE–41 BODY ELECTRICAL SYSTEM – INTERIOR LIGHT SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty. Trouble Parts name (See page) Only one interior light does not light up. 1. Bulb 2. Wire Harness Interior light does not light up (All). 1. DOME Fuse 2. Wire Harness (BE–4) 1. Integration Relay 2. Door Open Detection Switch 3. Door Outside Handle Switch 4. Door Courtesy Switch 5. Wire Harness (BE–42) (BE–93) (BE–43) (BE–43) ”Illuminated Entry System” does not operate. Interior light does not light up. 1. Bulb 2. Interior Light 3. Wire Harness (BE–43) Front personal light does not light up. 1. Bulb 2. Personal Light 3. Wire Harness (BE–42) Luggage compartment light does not light up. 1. Bulb 2. Back Door Courtesy Switch 3. Wire Harness (BE–44) Courtesy light does not light up. 1. Bulb 2. Door Open Detection Switch 3. Wire Harness (BE–94) BE–42 BODY ELECTRICAL SYSTEM – INTERIOR LIGHT SYSTEM PERSONAL LIGHT INSPECTION INSPECT PERSONAL LIGHT SWITCH Continuity Inspect the light switch continuity between terminals. Switch position Tester connection to terminal number OFF Specified value No continuity 1–2 1 –(4) Continuity The number in bracket ( ) applies to vehicles with Sliding Roof System. If continuity is not as specified, replace the light as– sembly or bulb. INTEGRATION RELAY INSPECTION INSPECT INTEGRATION RELAY Relay Circuit/ Illuminated Entry System Remove the relay from junction block and inspect the connector on the junction block side, as shown in the chart. Tester connection to terminal number Condition Specified value (Continuity) Door Outside Handle Switch Position OFF No continuity Door Outside Handle Switch Position ON Courtesy Switch Position OFF (except driver’s side) Continuity No continuity Courtesy Switch Position ON (except driver’s side) Continuity Constant Continuity Condition Specified value (Voltage) Constant Battery positive voltage Constant Battery positive voltage If circuit is as specified, trying replacing the relay with a new one. If the circuit is not as specified, inspect the circuits connected to other parts. BE–43 BODY ELECTRICAL SYSTEM – INTERIOR LIGHT SYSTEM DOOR OUTSIDE HANDLE SWITCH INSPECTION INSPECT DOOR OUTSIDE HANDLE SWITCH (a) Check that there is continuity between terminals 1 and 2 when door outside handle is pulled. (b) Check that there is no continuity between terminals 1 and 2 when door outside handle is released. If operation is not as specified, replace the switch. KIM–01 DOOR COURTESY SWITCH INSPECTION INSPECT DOOR COURTESY SWITCH (a) Check that there is continuity between terminal and switch body with the switch ON (switch pin released). (b) Check that there is no continuity between terminal and switch body with the switch OFF (switch pin pushed). If continuity is not as specified, replace the switch. BACK DOOR COURTESY SWITCH INSPECTION INSPECT BACK DOOR COURTESY SWITCH (a) Check that there is continuity between terminal 1 and 2 with the switch ON (switch pin released). (b) Check that there is no continuity between terminal 1 and 2 with the switch OFF (switch pin pushed). If continuity is not as specified, replace the switch. INTERIOR LIGHT SWITCH AND DECK ROOM LIGHT SWITCH INSPECTION INSPECT INTERIOR LIGHT SWITCH AND DECK ROOM LIGHT SWITCH Continuity Inspect the light switch continuity between terminals. Switch position Tester connection to terminal number DOOR 2 – Switch body Specified value Continuity No continuity OFF 1–2 Continuity If continuity is not as specified, replace the light as– sembly or bulb. BE–44 BODY ELECTRICAL SYSTEM – INTERIOR LIGHT SYSTEM LUGGAGE DOOR COURTESY SWITCH INSPECTION INSPECT LUGGAGE DOOR COURTESY SWITCH Continuity Inspect the switch continuity between terminal and switch body. Condition Tester connection to terminal number Switch OFF Switch ON Specified value No continuity 1 – Switch body Continuity If operation is not as specified, replace the switch. BE–45 BODY ELECTRICAL SYSTEM – BACK–UP LIGHT SYSTEM BACK–UP LIGHT SYSTEM PARTS LOCATION BE–46 BODY ELECTRICAL SYSTEM – BACK–UP LIGHT SYSTEM BE–47 BODY ELECTRICAL SYSTEM – BACK–UP LIGHT SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty. Trouble Parts name (See page) 1. GAUGE Fuse 2. Ignition Switch 3. Wire Harness 4. Bulb Back–Up Light does not light up. (BE–4) (BE–14) 1. Back–Up Light Switch (M/T) (BE–47) 2. Park/ Neutral Position Switch (A/T) 5S–FE (AX1–92) 1 MZ–FE (AX2– 116) Back–Up Light remains always on. 3. Wire Harness 1. Wire Harness 2. Bulb Only one light does not light up. BACK–UP LIGHT SWITCH INSPECTION INSPECT BACK–UP LIGHT SWITCH Inspect the switch continuity between terminals. Switch position Tester connection No continuity Free Push Specified value 1–2 Continuity If continuity is not as specified, replace the switch. PARK/ NEUTRAL POSITION SWITCH (5S–FE Engine) See page AX1–92. (lMZ–FE Engine) See page AX2–116. BE–48 BODY ELECTRICAL SYSTEM – STOP LIGHT SYSTEM STOP LIGHT SYSTEM PARTS LOCATION BE–49 BODY ELECTRICAL SYSTEM – STOP LIGHT SYSTEM BE–50 BODY ELECTRICAL SYSTEM – STOP LIGHT SYSTEM TROUBLESHOOTING The. table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty. Trouble (See page) Parts name Stop light does not light up. 1. STOP Fuse 2. Stop Light Switch 3. Wire Harness Only one light always lights up. 1. Wire Harness Only one light does not light. 1. Bulb 2. Wire Harness (BE–4) (BE–50) STOP LIGHT SWITCH INSPECTION INSPECT STOP LIGHT SWITCH Continuity Inspect the switch continuity between terminals. Switch position Tester connection to terminal number Specified value Switch pin free 1–2 Continuity Switch pin pushed in 3–4 Continuity If continuity is not as specified, replace the switch. BE–51 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM WIPER AND WASHER SYSTEM PARTS LOCATION BE–52 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty. Trouble Parts name (See page) Wiper and washers do not operate. 1. WIPER Fuse 2. Wiper Switch 3. Wiper Motor 4. Wire Harness (BE–4) (BE–53) (BE–56) Wipers do not operate in L0, HI or MIST. 1. Wiper Switch 2. Wiper Motor 3. Wire Harness (BE–53) (BE–56) Wipers do not operate in INT. 1. Wiper Switch 2. Wiper Motor 3. Wire Harness (BE–53) (BE–56) Washer motor does not operate. 1. Washer Switch 2. Washer Motor 3. Wire Harness (BE–53) (BE–58) Wipers do not operate when washer switch in ON. 1. Washer Motor 2. Wire Harness (BE–58) Washer fluid does not operate. 1. Washer Hose and Nozzle • • At wiper switch Hl position, the wiper blade is in contact with the 1. *1 Wiper Relay 2. Wire harness body. When the wiper switch is OFF, the wiper blade does not retract or the retract position wrong. *1: Inspect wiper arm and blade set position (BE–54) BE–53 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM COMBINATION SWITCH REMOVAL See page BO–108 COMBINATION SWITCH DISASSEMBLY See page BE–25. COMBINATION SWITCH ASSEMBLY See page BE–27. COMBINATION SWITCH INSTALLATION See page BO–108. COMBINATION SWITCH INSPECTION INSPECT WIPER AND WASHER SWITCH Continuity Inspect the switch continuity between terminals. WIPER OFF Switch position Tester connection to terminal number Specified value MIST OFF B4–B7 Continuity MIST ON B4–B7 B16–B18 Continuity WIPER INT Switch position MIST OFF MIST ON Tester connection to terminal number Specified value B4–B7 B14–B16 Continuity B4–B7 B14–B16–B18 Continuity WIPER LO Switch position Tester connection to terminal number Specified value MIST OFF B7–B18 Continuity MIST ON B7–B18 Continuity BE–54 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM WIPER HI Switch position Tester connection to terminal number Specified value MIST OFF B6 B16 B13–B18 Continuity MIST ON B6 B16 B13–B18 Continuity WASHER Switch position Tester connection to terminal number OFF No continuity B8–B16 Condition *1 Constant ”Apply B+ between terminals 16 and 18. Specified value Tester connection to terminal number Continuity Specified value B4 – B7 B16 – B18 Continuity B7–B18 Continuity *’: With wiper switch OFF or– INT, and MIST ON. If continuity is not as specified, replace the switch. Intermittent Wiper Operation (a) Turn the wiper switch to INT position. (b) Turn the intermittent time control switch to FAST position. (c) Connect the positive (+) lead from the battery to terminal 13– 18 and the negative (–) lead to terminal B –16. (d) Connect the positive (+) lead from the voltmeter to terminal B–7 and the negative (–) lead to terminal B –16, check that the meter needle indicates battery positive voltage. BE–55 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM (e) After connecting terminal B–4 to terminal B–18, connect to terminal B–16. Then, check that the voltage rises from 0 V to battery positive voltage within the times, as shown in the table. If operation is not as specified, replace the switch. I NT time control switch position Voltage FAST SLOW Non variable type Washer Linked Operation (a) Connect the positive (+) lead from the battery to terminal 13– 18 and the negative (–) lead to terminal B –16. (b) Connect the positive (+) lead from the voltmeter to terminal B–7 and the negative (–) lead to terminal B –16. (c) Push the washer switch, check that the voltage cha– nges, as shown in the table. If operation is not as specified, replace the wiper and washer switch. BE–56 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM WIPER RELAY INSPECTION WAGON Only: INSPECT REAR WIPER RELAY Continuity (a) Check that there is continuity between terminals 4 and 6. (b) Check that there is continuity between terminals 1 and 2. (c) Check that there is no continuity between terminals 1 and 4. If continuity is not as specified, replace the relay. Operation (a) Apply battery positive voltage across terminals 4 and 6. (b) Check that there is continuity between terminals 1 and 4. (c) Check that there is no continuity between terminals 1 and 2. If continuity is not as specified, replace the relay. WIPER MOTOR INSPECTION INSPECT MOTOR Operation at Low Speed Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 1, check that the motor operates at low speed. If operation is not as specified, replace the motor. Operation at High Speed Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor operates at high speed. If operation is not as specified, replace the motor. BE–57 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM Operation, Stopping at Stop Position (a) Operate the motor at low speed and stop the motor operation anywhere except at the stop position by disconnecting positive (+) lead from terminal 3. (b) Connect terminals 3 and 5. (c) Connect the positive (+) lead from the battery to terminal 6 and negative (–) lead to terminal 1, check that the motor stops running at the stop position after the motor operates again. If operation is not as specified, replace the motor. REAR WIPER MOTOR INSPECTION WAGON Only: INSPECT MOTOR Operation at Low Speed Connect the positive (+) lead from the battery to terminal 4 and the negative (–) lead to terminal 2, check that the motor operates at low speed. If operation is not as specified, replace the motor. Operation, Stopping at Stop Position (a) Operate the motor at low speed and stop the motor operation anywhere except at the stop position by disconnecting positive (+) lead from terminal 4. (b) Connect terminals 3 and 4. (c) Connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 2, check that the motor stops running at the stop position after the motor operates again. If operation is not as specified, replace the motor. BE–58 BODY ELECTRICAL SYSTEM – WIPER AND WASHER SYSTEM WASHER MOTOR INSPECTION (WAGON Only) INSPECT WASHER MOTOR Front Washer Operation Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor operates. NOTICE: These tests must be performed quickly (within 20 seconds) to prevent the coil from burning out. If operation is not as specified, replace the motor. Rear Washer Operation Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 3, check that the motor operates. NOTICE: These tests must be performed quickly (within 20 seconds) to prevent the coil from burning out. If operation is not as specified, replace the motor. (Ex. WAGON) INSPECT WASHER MOTOR Operation Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor operates. NOTICE: There tests must be performed quickly (within 20 seconds) to prevent the coil from burning out. If operation is not as specified, replace the motor. BE–59 BODY ELECTRICAL SYSTEM – COMBINATION METER COMBINATION METER PARTS LOCATION BE–60 BODY ELECTRICAL SYSTEM – COMBINATION METER WIRING DIAGRAM BE–61 BODY ELECTRICAL SYSTEM – COMBINATION METER No. Wiring Connector Side 1 2 3 4 5 6 7 8 9 10 11 12 13 Headlight dimmer and turn signal switch Headlight dimmer and turn signal switch Ground ECM Ground Ground Fuel sender gauge–terminal 2 Fuel sender gauge–terminal 3 Cruise Control ECU 0/D OFF Switch Electronic Controlled Transaxle (PWR) Speed sensor Light control rheostat 3 4 5 fi 7 8 9 10 11 12 13 14 15 16 Light failure sensor DOME fuse Door courtesy switch GAUGE fuse Integration relay Generator IG2 fuse Oil pressure switch Igniter Parking brake switch and brake fluid level warning switch Headlight dimmer switch Headlight dimmer switch Starter relay TAIL fuse 1 2 3 4 7 8 Center Airbag Sensor Assembly ECU–13 fuse ECM ABS ECU Engine coolant temperature sender gauge Ground BE–62 BODY ELECTRICAL SYSTEM – COMBINATION METER A/T SHIFT POSITION INDICATOR No. Wiring Connector Side 1 2 3 4 5 6 7 8 9 10 11 13 Light control rheostat TAIL fuse Park/Neutral Position switch Park/Neutral Position switch Park/Neutral Position switch Ground Park/Neutral Position switch GAUGE fuse 0/D switch Park/Neutral Position switch Park/Neutral Position switch Electronic Controlled Transaxle select switch (PWR) BE–63 BODY ELECTRICAL SYSTEM – COMBINATION METER TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty. METER, GAUGES AND ILLUMINATION Trouble Tachometer, Voltmeter, Fuel Gauge and Engine Coolant Temperature Gauge do not operate. Speedometer does not operate. Parts name (See page) 1. GAUGE Fuse 2. Combination Meter Wiring Circuit 3. Wire Harness 4. Meter Circuit Plate (BE–4) (BE–61) (BE–60) 1. No. 1 vehicle speed Sensor 2. Speedometer Driven Gear and Drive Gear (BE–67) 1. Combination Meter Wiring Circuit 2. Wire Harness 3. Igniter (BE–61) Tachometer does not operate. 5S–FE (IG–12, 31) 1 MZ–FE (IG–49) (BE–60) 4. Meter Circuit Plate Fuel Gauge does not operate or abnormal operation. 1. Fuel Receiver Gauge 2. Fuel Sender Gauge 3. Combination Meter Wiring Circuit 4. Wire Harness Engine Coolant Temperature Gauge does not operate or abnormal operation. 1. Engine Coolant Temperature Receiver Gauge (BE–70) 2. Engine Coolant Temperature Sender Gauge (BE–70) 3. Combination Meter Wiring Circuit (BE–61) 4. Wire Harness All illumination lights do not light up. 1. TAIL Fuse 2. Light Control Rheostat 3. Wire Harness Brightness does not change even when rheostat turned. 1. Bulb 2. Wire Harness Only one illumination light does not light up. 1. Bulb 2. Wire Harness (BE–68) (BE–69) (BE–61) (BE–4) (BE–77) BE–64 BODY ELECTRICAL SYSTEM – COMBINATION METER WARNING LIGHTS Trouble Parts name (See page) (BE–4) (BE–61) Warning light do not fight up. (Except. Discharge) 1. GAUGE Fuse 2. Combination Meter Wiring Circuit 3. Wire Harness Low Oil Pressure warning light does not light up. 1. Bulb 2. Combination Meter Wiring Circuit 3. Low Oil Pressure Warning Switch 4. Wire Harness Fuel Level warning light does no light up. 1. Bulb 2. Combination Meter Wiring Circuit 3. Fuel Level Warning Switch A6S warning light does no light up. 1. Bulb 2. ABS ECU 3. Wire Harness (BR–90) Malfunction warning light does not light up. 1. Bulb 2. ECM 3. Wire Harness (EG–394) Seat Belt warning light does not light up. 1. Bulb 2. Integration Relay 3. Wiring Harness Discharge warning light does not light up. 1. IG N Fuse 2. Bulb 3. Wire Harness 4. Generator (BE–61) (BE–71) (BE–61) (BE–69) (BE–31) (BE–4) 5S–FE (CH–7) 1 MZ–FE (CH–31) Light Failure warning light does no light up. 1. Bulb 2. Light Failure Sensor 3. Wire Harness 4. ”Taillight system” Brake warning light does not light up. 1. Bulb 2. Combination Meter Wiring Circuit 3. Parking Brake Switch 4. Brake Fluid Level Warning Switch SRS warning light does not light up. 1. ECU – B Fuse 2. Bulb 3. Wire Harness 4. Center Airbag Sensor Assembly Open Door warning light does not light up. 1. Bulb 2. Combination Meter Wiring Circuit 3. Door Courtesy Switch (BE–73) (BE–17) (BE–61) (BE–72) (BE–71) (BE–4) (RS–55) (BE–61) (BE–43) BE–65 BODY ELECTRICAL SYSTEM – COMBINATION METER INDICATOR LIGHTS Trouble O/D OFF indicator light does not light up. (see page) Parts name 1. Bulb 2. Combination Meter Wiring Circuit (BE–61) 3. O/D OFF Switch 5S–FE (AX1–102) 1 MZ–FE (AX2–130) 4. Wire Harness Cruise Control indicator light does not light up. 1. Bulb 2. Cruise Control ECU 3. Wire Harness High beam indicator light does not light up. 1. Bulb 2. Combination Meter Wiring Circuit 3. Wire Harness 4. ”Headlight System” Turn indicator light does not light up. Electrically Controlled Transmission PWR indicator lights does not light up. (BE–176) (BE–61) (BE–17) 1. Bulb 2. Combination Meter Wiring Circuit 3. Wire Harness 4. ”Turn Signal and Hazard Warning System” 1. Bulb 2. Combination Meter Wiring Circuit 3. TCM Pattern Select Switch (BE–61) (BE–35) (BE–61) 5S–FE (AX1–98) 1 MZ– FE (AX2–126) 4. Wire Harness 1. Bulb 2. Combination Meter Wiring Circuit 3. Park / Neutral Position Switch Shift indicator lights do not light up. (All) (BE–61) 5S–FE (AX1–92) 1 MZ– FE (AX2–116) 4. Wire Harness 1. Bulb 2. Combination Meter Wiring Circuit 3. Park / Neutral Position Switch (BE–61) 5S–FE (AX1–92) 1 MZ– FE (AX2–116) Shift indicator lights do not light up. (L. 2. D) 4. Light Control Rheostat 5. Wire Harness Only one shift indicator does not light up. 1. Bulb 2. Combination Meter Wiring Circuit Indicator lights do not light up. (Except. Turn, Hi–beam) 1. GAUGE Fuse 2. Wire Harness (BE–77) (BE–61) (BE–4) BE–66 BODY ELECTRICAL SYSTEM – COMBINATION METER SPEEDOMETER INSPECTION ON–VEHICLE Using a speedometer tester, inspect the speedometer for allowable indication error and check the operation of the odometer. HINT: Tire wear and tire over or under inflation will increase the indication error. If error is excessive, replace the speedometer. mph/ USA: Standard indication Allowable range km/h/ CANADA: Standard indication Allowable range BE–67 BODY ELECTRICAL SYSTEM – COMBINATION METER SPEED SENSOR INSPECTION Operation (a) Connect the positive (+) lead from battery to terminal 1 and negative (–) lead to terminal 2. (b) Connect the positive (+) lead from tester to terminal 3 and negative (–) lead to terminal 2. (c) Revolve shaft. (d) Check that there is voltage change from approx. 0 V to 1 1 V or more between terminals 2 and 3. HINT: The voltage change should be 4 times par each revolution of the speed sensor shaft. If operation is not as specified, replace the sensor. BE–68 BODY ELECTRICAL SYSTEM – COMBINATION METER TACHOMETER INSPECTION ON–VEHICLE (a) Connect a tune–up test tachometer, and start the engine. NOTICE: Reversing the connection of the tachometer will damage the transistors and diodes inside. (b) Compare the tester and tachometer indications. If error is excessive, replace the tachometer. DC 13.5 V, 25
C (77
F)/ rpm Standard indication Allowable range FUEL RECEIVER GAUGE INSPECTION Operation (a) Disconnect the connector from the sender gauge as– sembly. (b) Turn the ignition switch ON, check that the receiver gauge needle indicates EMPTY. (c) Connect terminals 2 and 3 on the wire harness side connector through a 3.4 w test bulb. (d) Turn the ignition switch ON, check that the bulb lights up and receiver gauge needle moves toward the full side. HINT: Because of the silicon oil in the gauge, it will take a short time for the needle to stabilize. If operation is not as specified, inspect the receiver gauge resistance. Resistance Measure the resistance between terminals. Between terminals Resistance (Ω ) A–B Approx. 126 A–C B–C Approx. 281 Approx. 154 If resistance value is not as specified, replace the fuel receiver gauge. BE–69 BODY ELECTRICAL SYSTEM – COMBINATION METER FUEL SENDER GAUGE INSPECTION Operation (a) Connect a series of three 1.5 V dry cell batteries. (b) Connect the positive (+) lead from the dry cell batte– ries to terminal 2 through a 3.4 W test bulb and the negative (–) lead to terminal 3. (c) Check that the voltage rises between terminals 2 and 3 as the float is moved from the top to bottom posi– tion. Resistance Measure the resistance between terminals 2 and 3 for each float position. Float position mm (in.) Approx. 35.5 (1.40) 1/2 Resistance (Ω) Approx. 90.9 (3.59) Approx. 3 Approx. 30.8 Approx. 157.4 (6.20) Approx. 110 If resistance value is not as specified, replace the sender gauge. FUEL LEVEL WARNING LIGHT INSPECTION INSPECT FUEL LEVEL WARNING LIGHT a) Disconnect the connector from the sender gauge. b) Connect terminals 1 and 3 on the wire harness side connector. e) Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, test the bulb or inspect wire harness. FUEL LEVEL WARNING SWITCH INSPECTION INSPECT FUEL LEVEL WARNING SWITCH (a) Apply battery positive voltage between terminals 1 and 3 through a 3.4 W test bulb, check that the bulb lights up. HINT: It will take a short time for the bulb to light up. BE–70 BODY ELECTRICAL SYSTEM – COMBINATION METER (b) Submerge the switch in fuel, check that the bulb goes out. If operation is not as specified, replace the sender gauge. ENGINE COOLANT TEMPERATURE RECEIVER GAUGE AND SENDER GAUGE INSPECTION Operation (a) Disconnect the connector from the sender gauge. (b) Turn the ignition switch ON, check that the receiver gauge needle indicates COOL. (c) Ground terminal on the wire harness side connector through a 3.4W test bulb. (d) Turn the ignition switch ON, check that the bulb lights up and the receiver gauge needle moves toward the hot side. If operation is as specified, replace the sender gauge. Then recheck the system. If operation is not as specified, measure the receiver gauge resistance. Resistance Measure the resistance between terminals. HINT: Connect the test leads so that the current from the ohmmeter can flow according to the chart order. Between terminals Resistance (Ω) A–B Approx. 54 A–C Approx. 176 B–C Approx. 230 If resistance value is not as specified, replace the engine coolant temperature receiver gauge. BE–71 BODY ELECTRICAL SYSTEM – COMBINATION METER LOW OIL PRESSURE WARNING LIGHT INSPECTION INSPECT LOW OIL PRESSURE WARNING LIGHT (a) Disconnect the connector from the warning switch and ground terminal on the wire harness side connec– tor. (b) Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, test the bulb or inspect wire harness. LOW OIL PRESSURE WARNING SWITCH INSPECTION INSPECT LOW OIL PRESSURE WARNING SWITCH (a) Check that there is continuity between terminal and ground with the engine stopped. (b) Check that there is no continuity between terminal and ground with the engine running. HINT: Oil pressure should be over 29 kPa (0.3 kgf/ cm2, 4.3 psi) If operation is not as specified, replace the switch. BRAKE FLUID LEVEL WARNING LIGHT INSPECTION INSPECT BRAKE WARNING LIGHT (a) Disconnect the connector from the brake fluid warn– ing switch. (b) Release the parking brake pedal. (c) Connect terminals on the wire harness side of the level warning switch connector. (d) Start the engine, check that the warning light lights up. If the warning light does not light up, test the bulb or wire harness. BE–72 BODY ELECTRICAL SYSTEM – COMBINATION METER BRAKE FLUID LEVEL WARNING SWITCH INSPECTION INSPECT BRAKE FLUID LEVEL WARNING SWITCH (a) Remove the reservoir tank cap and strainer. (b) Disconnect the connector. (c) Check that there is no continuity between terminals with the switch OFF (float up). (d) Use syphon, etc. to take fluid out of the reservoir tank. (e) Check that there is continuity between terminals with the switch ON (float down). (f) Pour the fluid back in the reservoir tank. If operation is not as specified, replace the switch. PARKING BRAKE SWITCH INSPECTION INSPECT PARKING BRAKE SWITCH (a) Check that there is continuity between terminal and switch body with the switch ON (switch pin released). (b) Check that there is no continuity between terminal and switch body with the switch OFF (switch pin pushed in). If operation is not as specified, replace the switch or inspect ground point. LIGHT FAILURE WARNING LIGHT INSPECTION INSPECT LIGHT FAILURE WARNING LIGHT (a) Disconnect the connector from the light failure sensor and ground terminal 4 on the wire harness side con– nector. (b) Start the engine, check that the warning light lights up. If the warning light does not light up, test the bulb or inspect wire harness. BE–73 BODY ELECTRICAL SYSTEM – COMBINATION METER LIGHT FAILURE SENSOR INSPECTION INSPECT LIGHT FAILURE SENSOR Relay Circuit Disconnect the connector from the sensor and in– spect the connector on the wire harness side, as shown. Tester connection to terminal number Condition Specified value (Continuity) Constant * Continuity Constant Constant * Continuity * Continuity Constant Continuity Condition Specified value (Voltage) Light control switch position OFF No voltage Light control switch position TAIL or HEAD Battery positive voltage Engine condition Stop No voltage Engine condition Running Battery positive voltage Ignition switch position LOCK or ACC No voltage Ignition switch position ON Battery positive voltage Stop light switch position OFF No voltage Stop light switch position ON Battery positive voltage *: There is resistance because this circuit is grounded through the bulb. If circuit is as specified, replace the sensor. If the circuit is not as specified, inspect the circuits connect– ed to other parts. BE–74 BODY ELECTRICAL SYSTEM – COMBINATION METER OPEN DOOR WARNING LIGHT INSPECTION INSPECT OPEN DOOR WARNING LIGHT Disconnect the connector from the door courtesy switch, and ground terminal 1 on the wire harness side connector and check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. DOOR COURTESY SWITCH See page BE–43. SEAT BELT WARNING LIGHT INSPECTION INSPECT SEAT BELT WARNING LIGHT (a) Remove the integration relay from the junction block No. 1. (b) Ground terminal A9 on the junction block side con– nector. (c) Turn the ignition switch ON, check that the warning light lights up. If the warning light does not light up, inspect the bulb or wire harness. BE–75 BODY ELECTRICAL SYSTEM – COMBINATION METER INTEGRATION RELAY INSPECTION INSPECT INTEGRATION RELAY Operation/ Seat belt warning (a) Connect the positive (+) lead from the battery to terminals Al and A7. (b) Connect the terminal A7 to terminal A9 through the 3.4 W test bulb. (c) Connect the negative (–) lead from the battery to terminal Al 0. (d) Check that the bulb lights and the chime sounds for 4 – 8 seconds. (e) Return to step (a), and operate the chime again. (f) Connect the negative (–) lead from the battery to terminal A8. (g) Check that the chime stops sounding. HINT: Check the chime within a period of 4 to 8 seconds. If operation is not as specified, replace the relay. Relay circuit/ Seat belt warning Remove the relay from the junction block No.1 and inspect the connectors on the junction block side. Tester connection to terminal number Condition Specified value (Continuity) A8 – Ground Driver’s buckle switch OFF (Seat best unfastened) No continuity A8 – Ground Driver’s buckle switch ON (Seat best fastened) Continuity A10 – Ground Constant Continuity BE–76 BODY ELECTRICAL SYSTEM Tester connection to terminal number – COMBINATION METER Condition Specified value (Voltage) A1 – Ground Constant Battery positive voltage A7 – Ground A9 – Ground Ignition switch position OFF or ACC No voltage A7 – Ground A9 – Ground Ignition switch position ON Battery positive voltage If circuit is as specified, trying replacing the relay with a new one. Is circuit is not as specified, inspect the circuits con– nected to other parts. BUCKLE SWITCH INSPECTION INSPECT BUCKLE SWITCH w/o POWER SEAT: Continuity (a) Check that there is continuity between terminals on the switch side connector with the switch ON (belt fastened). (b) Check that there is no continuity between terminals on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner belt. BE–77 BODY ELECTRICAL SYSTEM – COMBINATION METER w/ POWER SEAT: Continuity (a) Check that there is continuity between terminals 1 and 2 on the switch side connector with the switch ON (belt fastened). ’ (b) Check that there is no continuity between terminals 1 and 2 on the switch side connector with the switch OFF (belt unfastened). If operation is not as specified, replace the seat belt inner belt. METER ILLUMINATION CONTROL SYSTEM INSPECT LIGHT CONTROL RHEOSTAT (a) Connect terminals 1 and 3 through a 3.4 W test bulb. (b) Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2. (c) Turn the rheostat knob to fully counterclockwise, check that the test bulb goes out. (d) Gradually turn the rheostat knob to clockwise, check that the test bulb brightness changes from dark to bright. If operation is not as specified, replace the rheostat. BULB CHECK RELAY INSPECTION INSPECT BULB CHECK RELAY (a) Connect the positive (+) lead from the battery to terminal C through a 1.4 W test bulb and the negative (–) lead to terminal B, check that the test bulb does not light up. (b) Connect the positive (+) lead from the battery to terminal A , check that the test bulb light up. If operation is not as specified, replace the relay. BE–78 BODY ELECTRICAL SYSTEM – DEFOGGER SYSTEM DEFOGGER SYSTEM PARTS LOCATION BE–79 BODY ELECTRICAL SYSTEM – DEFOGGER SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty. Trouble All defogger systems do not operate. Rear window defogger does not operate. (See page) Paris name 1. DEFOG M – Fuse 2. GAUGE Fuse 3. Defogger Relay 4. Defogger Switch 5. Wire Harness (BE–4) (BE–4) (BE–80) (BE–79) 1. Defogger Wire 2. Choke Coil 3. Wire Harness (BE–80) DEFOGGER SWITCH INSPECTION INSPECT DEFOGGER SWITCH Continuity Inspect the switch continuity between terminals. Condition Tester connection to terminal number No continuity Switch OFF Switch ON Illumination circuit Specified value 3–6 4–5 Continuity Continuity If continuity is not as specified, check the bulb or replace the switch. INDICATOR LIGHT OPERATION Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 1, check that the indicator light does not light up, replace the switch. BE–80 BODY ELECTRICAL SYSTEM – DEFOGGER SYSTEM DEFOGGER RELAY INSPECTION INSPECT DEFOGGER RELAY Continuity Inspect the relay continuity between terminals. Condition Tester connection to terminal number Constant Apply B + between terminals 1 and 2. Specified value 1–2 Continuity 3–5 Continuity If continuity is not as specified, replace the relay. DEFOGGER WIRE INSPECTION NOTICE: • When cleaning the glass, use a soft, dry cloth, and wipe the glass in the direction of the wire. Take care not to damage the wires. • Do not use detergents or glass cleaners with abra– sive ingredients. • When measuring voltage, wind a piece of tin foil around the top of the negative probe and press the foil against the wire with your finger, as shown. (a) Turn the ignition switch ON. (b) Turn the defogger switch ON. (c) Inspect the voltage at the center of each heat wire, as shown. Voltage Approx. 5V Approx. 1 OV or OV Criteria Okay (No break in wire) Broken wire HINT: If there is approximately 10 V, the wire is broken between the center of the wire and the posi– tive (+) end. If there is no voltage, the wire is broken between the center of the wire and ground. BE–81 BODY ELECTRICAL SYSTEM – DEFOGGER SYSTEM (d) Place the voltmeter positive (+) lead against the def– ogger positive (+) terminal. (e) Place the voltmeter negative (–) lead with the foil strip against the heat wire at the positive (+) terminal end and slide it toward the negative (–) terminal end. (f) The point where the voltmeter deflects from zero to several V is the place where the heat wire is broken. HINT: If the heat wire is not broken, the voltmeter indicates 0 V at the positive (+) end of the heat wire but gradually increases to about 12 V as the meter probe is moved to the other end. DEFOGGER WIRE REPAIR (a) Clean the broken wire tips with a grease, wax and silicone remover. (b) Place the masking tape along both sides of the wire to be repaired. (c) Thoroughly mix the repair agent (Dupont paste No. 4817). (d) Using a fine tip brush, apply a small amount to the wire. (e) After a few minutes, remove the masking tape. (f) Allow the repair to stand at least 24 hours. BE–82 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM POWER WINDOW CONTROL SYSTEM PARTS LOCATION BE–83 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty. Trouble Parts name (See page) 1. ALT H –Fuse 2. P/V11 M–Fuse 3. Wire Harness (BE–4) (BE–4) 1. GAUGE Fuse 2. Ignition Switch 3. P/W M–Fuse 4. Power Main Relay 5. Power Window Master Switch 6. Wire Harness (BE–4) (BE–14) (BE–4) (BE–89) (BE–84) ”One Touch Power Window System” does not operate. 1. Power Window Master Switch (BE–84) Only one window glass does not move. 1. Power Window Master Switch 2. Power Window Switch 3. Power Window Motor 4. Wire Harness (BE–84) (BE–87) (BE–87) ”Window Lock System” does not operate. 1. Power Window Master Switch (BE–84) ”Window Lock Illumination” does not light up. 1. Power Window Master Switch (BE–84) Key–off power window does not operate. 1. DOME Fuse 2. GAUGE Fuse 3. Ignition Switch 4. Door Open Detection Switch 5. Wire Harness (BE–4) (BE–4) (BE–14) (BE–94) *1 Power window does not operate. *2 Power window does not operate. *1: Door Lock does not operate. *2: Door Lock is normal. BE–84 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM POWER WINDOW MASTER SWITCH INSPECTION INSPECT POWER WINDOW MASTER SWITCH Continuity Inspect the switch continuity between terminals. Front Driver’s Switch (Window unlock)/ Continuity Switch position OFF DOWN Tester connection to terminal number Specified value 6–7–8 1 –2–13 Continuity 1–2–6–13 Continuity 1–2–6 7–8–13 Continuity Front Driver’s Switch (Window lock)/ Continuity Switch position OFF DOWN Tester connection to terminal number Specified value 6–7–8 1–2–13 Continuity 1–2–6–13 Continuity 1–2–6 7–8–13 Continuity Front Passenger’s Switch (Window unlock)/ Conti– nuity Switch position OFF DOWN Tester connection to terminal number Specified value 7–8–12 Continuity 5–12 Continuity 5–7–8 Continuity Front Passenger’s Switch (Window lock)/ Continui– ty Switch position OFF DOWN Tester connection to terminal number Specified value 1–2–5 7–8–12 Continuity 1–2–5–12 Continuity 5–7–8 1–2–12 Continuity BE–85 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM Rear Left Switch (Window unlock)/ Continuity Switch position Tester connection to terminal number Specified value 7–8–10 Continuity OFF 9–10 Continuity DOWN 7–8–9 Continuity Rear Left Switch (Window lock)/ Continuity Switch position OFF DOWN Tester connection to terminal number Specified value 7–8–10 1–2–9 Continuity 1–2–9–10 Continuity 7–8–9 1–2–10 Continuity Rear Right Switch (Window unlock)/ Continuity Switch position Tester connection to terminal number 7–8–11 OFF DOWN Specified value Continuity 11–14 Continuity 7–8–14 Continuity Rear Right Switch (Window lock)/ Continuity Switch position Tester connection to terminal number 7–8–11 1–2–14 OFF DOWN 1–2–11–14 7–8–14 1–2–11 Specified value Continuity Continuity Continuity If continuity is not as specified, relace the master switch. BE–86 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM Illumination (a) Set the window lock switch to the unlock position. (b) Connect the positive (+) lead from the battery to terminal 7 and the negative (–) lead to terminal 1, check that all the illuminations light up. (c) Set the window lock switch to the lock position, check that all the passenger’s power window switch illumi– nations go out. If operation is not as specified, replace the master switch. One Touch Power Window System/ Current of Cir– cuit Inspection using an ammeter. (a) Disconnect the connector from the master switch. (b) Connect the positive (+) lead from the ammeter to terminal 6 on the wire harness side connector and the negative (–) lead to negative terminal of the battery. (c) Connect the positive (+) lead from the battery to terminal 13 on the wire harness side connector. (d) As the window goes down, check that the current flow is approximately 7 A. (e) Check that the current increases approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens some 4 – 40 seconds after the window stops going down, so that check must be made before the circuit breaker operates. If the operation is as specified, replace the master switch. Inspection using an ammeter with a current–meas– uring probe. (a) Remove the master switch with connector connected. (b) Attach a current–measuring probe to terminal 6 of the wire harness. (c) Turn the ignition switch ON and set the power window switch in the down position. (d) As the window goes down, check that the current flow is approximately 7 A. BE–87 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM (e) Check that the current increases approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens some 4 – 40 seconds after the window stops going down, so that check must be made before the circuit breaker operates. If operation is as specified, replace the master switch. POWER WINDOW SWITCH INSPECTION INSPECT POWER WINDOW SWITCH Switch Continuity Inspect the switch continuity between terminals. Switch position Tester connection to terminal number Specified value 1–5 3–4 Continuity OFF 1–Z 3–4 Continuity DOWN 1–2 4–5 Continuity If continuity is not as specified, replace the switch. POWER WINDOW MOTOR INSPECTION INSPECT POWER WINDOW MOTOR Driver’s Door Motor/ Motor Operation (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the motor turns clockwise. (b) Reverse the polarity, check that the motor turns coun– terclockwise. If operation is not as specified, replace the motor. Driver’s Door Motor/ Circuit Breaker Operation (a) Disconnect the connector from the master switch. (b) Connect the positive (+) lead from the battery to terminal 6 and the negative (–) lead to terminal 13 on the wire harness side connector and raise the window to full closed position. (c) Continue to apply voltage, check that there is a circuit breaker operation noise within approximately 4 to 40 seconds. BE–88 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM (d) Reverse the polarity, check that the window begins to descend within approximately 60 seconds. If operation is not as specified, replace the motor. Front Passenger’s Door Motor/ Motor Operation (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the motor turns counterclockwise. (b) Reverse the polarity, check that the motor turns clo– ckwise. If operation is not as specified, replace the motor. Front Passenger’s Door Motor/ Circuit Breaker Op– eration (a) Disconnect the connector from the power window switch. (b) Connect the positive (+) lead from the battery to terminal 4 and the negative (–) lead to terminal 1 on the wire harness side connector, and raise the window to full closed position. (c) Continue to apply voltage, check that there is a circuit breaker operation noise within approximately 4 to 40 seconds. (d) Reverse the polarity, check that the window begins to descend within approximately 60 seconds. If operation is not as specified, replace the motor. BE–89 BODY ELECTRICAL SYSTEM – POWER WINDOW CONTROL SYSTEM Rear Left Side Door Motor/ Motor Operation (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2. check that the motor turns clockwise. (b) Reverse the polarity, check that the motor turns coun– terclockwise. If operation is not as specified, replace the motor. Rear Left Side Door Motor/ Circuit Breaker Opera– tion See step of Front Passenger Door Motor on page BE–88. Rear Right Side Door Motor/ Motor Operation (a) Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 1, check that the motor turns counterclockwise. (b) Reverse the polarity, check that the motor turns clo– ckwise. If operation is not as specified, replace the motor. Rear Right Side Door Motor/ Circuit Breaker Opera– tion See step of Front Passenger Door Motor on page BE–88. POWER MAIN RELAY INSPECTION INSPECT POWER MAIN RELAY Continuity Inspect the relay continuity between terminals. Condition Constant Apply B + between terminals t and 2. Tester connection to terminal number Specified value 1–2 Continuity 3–5 Continuity If continuity is not as specified, replace the relay. BE–90 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM POWER DOOR LOCK CONTROL SYSTEM PARTS LOCATION BE–91 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM BE–92 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty. Trouble Parts name (See page) ”Door lock system” does not operate at all. 1. POWER Fuse 2. RADIO/CIG Fuse 3. Door Lock Control Relay 4. Wire Harness (BE–4) (BE–4) (BE–98) Door lock system does not operate by manual switch. 1. Power Window Master Switch 2. Door Lock Manual Switch 3. Door Lock Control Relay 4. Wire Harness (BE–93) (BE–93) (BE–98) Door lock system does not operate by door key. 1. Door Key Lock and Unlock Switch 2. Door Lock Control Relay 3. Wire Harness 4. Door Lock Link Disconnected (BE–94) (BE–98) Fault in 2–Operation unlock function of Driver’s side door key lock and unlock switch. 1. Door Key Lock and Unlock Switch 2. Door Lock Control Relay 3. Wire Harness (BE–94) (BE–98) Fault in key confine prevention operate. 1. Door Lock Control Relay 2. Key Unlock Warning Switch 3. Door Courtesy Switch 4. Wire Harness (BE–98) (BE–15) (BE–43) Only one door lock does not operate. 1. Door Lock Motor 2. Wire Harness (BE–94) BE–93 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM POWER WINDOW MASTER SWITCH INSPECTION INSPECT POWER WINDOW MASTER SWITCH Master Switch: Driver’s Door Lock Manual Switch/ Continuity Inspect the switch continuity between terminals. Switch position LOCK Tester connection to terminal number 1–2–4 OFF UNLOCK Specified value Continuity No continuity 1–2–3 Continuity If continuity is not as specified, replace the switch. DOOR LOCK MANUAL SWITCH INSPECTION INSPECT DOOR LOCK MANUAL SWITCH Continuity Inspect the switch continuity between terminals. Switch position LOCK Tester connection to terminal number 3–4 OFF UNLOCK Specified value Continuity No continuity 2–4 Continuity If continuity is not as specified, replace the switch. BE–94 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM DOOR KEY LOCK AND UNLOCK SWITCH INSPECTION INSPECT DOOR KEY LOCK AND UNLOCK SWITCH Continuity Inspect the switch continuity between terminals. Switch position LOCK Tester connection to terminal number 2–3 OFF UNLOCK Specified value Continuity No continuity 1–2 Continuity If continuity is not as specified, replace the switch. HINT: Door key lock and unlock switch is built into the front door lock assembly. KEY UNLOCK WARNING SWITCH See key confine prevention system on page BE–15. DOOR COURTESY SWITCH See open door warning system on page BE–43. DOOR LOCK MOTOR INSPECTION (DOOR OPEN DETECTION SWITCH INSPECTION) INSPECT DOOR LOCK MOTOR Motor Operation (a) Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 4, check that the door lock link moves to UNLOCK posi– tion. (b) Remove the polarity, check that the door lock link move to LOCK position. If operation is not as specified, replace the door lock assembly. BE–95 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM Ex. WAGON: PTC THERMISTOR OPERATION INSPECTION USING AN AMMETER (a) Connect the positive (+) lead from the battery to terminal 2. (b) Connect the positive (+) lead from the ammeter to terminal 4 and the negative (–) lead to battery nega– tive (–) terminal, check that the current changes from approximately 3.2 ampere to less than 0.5 ampere with 20 to 70 seconds. (c) Disconnect the leads from terminals. (d) Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 4 and the nega– tive (–) lead to terminal 2 check that the door lock moves to LOCK position. If operation is not as specified, replace the door lock assembly. Ex. WAGON: INSPECTION USING AN AMMETER WITH A CUR– RENT–MEASURING PROBE (a) Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 4. (b) Attach a current–measuring probe to either the pos– itive (+) lead or the negative (–) lead, check that the current changes from approximately 3.2 ampere to less than 0.5 ampere within 20 to 70 seconds. (c) Disconnect the leads from terminals. (d) Approximately 60 seconds later, reverse the polarity, check that the door lock moves to LOCK position. If operation is not as specified, replace the door lock assembly. BE–96 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM WAGON Only: PTC THERMISTOR OPERATION INSPECTION USING AN AMMETER (a) Connect the positive (+) lead from the battery to terminal 2. (b) Connect the positive (+) lead from the ammeter to terminal 4 and the negative (–) lead to battery nega– tive (–) terminal, check that the current changes from approximately 3.2 ampere to less than 0.5 ampere with 20 to 70 seconds. (c) Disconnect the leads from terminals. (d) Approximately 60 seconds later, connect the positive (+) lead from the battery to terminal 4 and the nega– tive (–) lead to terminal 2 check that the door lock moves to LOCK position. If operation is not as specified, replace the door lock assembly. WAGON Only: INSPECTION USING AN AMMETER WITH A CUR– RENT–MEASURING PROBE (a) Connect the positive (+) lead from the battery to terminal 2 and the negative (–) lead to terminal 4. (b) Attach a current–measuring probe to either the pos– itive (+) lead or the negative (–) lead, check that the current changes from approximately 3.2 ampere to less than 0.5 ampere within 20 to 70 seconds. (c) Disconnect the leads from terminals. (d) Approximately 60 seconds later, reverse the polarity, check that the door lock moves to LOCK position. If operation is not as specified, replace the door lock assembly. BE–97 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM DOOR UNLOCK DETECTION SWITCH INSPECTION INSPECT DOOR UNLOCK DETECTION SWITCH Continuity Inspect the switch continuity between terminals. Switch position Tester connection to terminal number OFF (Door lock set to LOCK) ON (Door lock set to UNLOCK) Specified value No continuity 1–3 Continuity If continuity is not as specified, replace the door lock assembly. BACK DOOR UNLOCK DETECTION SWITCH INSPECTION WAGON Only: INSPECT BACK DOOR UNLOCK DETECTION SWITCH Continuity Inspect the switch continuity between terminals. Switch position Tester connection to terminal number OFF (Door lock set to LOCK) ON (Door lock set to UNLOCK) Specified value No continuity 1–3 Continuity If continuity is not as specified, replace the door lock assembly. POWER MAIN RELAY See power main relay on page BE–89. BE–98 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM DOOR LOCK CONTROL RELAY INSPECTION INSPECT DOOR LOCK CONTROL RELAY Relay Circuit Disconnect the connector from the relay and inspect the connector on the wire harness side, as shown in the chart. Tester connection to terminal number Condition Specified value (Continuity) Driver’s door courtesy switch position OFF (Door closed) No continuity Driver’s door courtesy switch position ON (Door opened) Continuity Passenger’s Door Lock Switch position OFF No continuity (Door locked) Passenger’s Door Lock Switch position ON Continuity (Door unlocked) Driver’s Door Lock Switch position OFF (Doorlocked) No continuity Driver’s Door Lock Switch position ON (Door unlocked) Continuity Key Unlock Warning Switch position OFF (Ignition Key Removed) No continuity Key Unlock Warning Switch position ON (ignition Key Set) Continuity Driver’s Door Key Lock and Unlock Switch Position OFF or LOCK (Door key free or turned to lock) No continuity Driver’s Door Key Lock and Unlock Switch Position UNLOCK (Door key turned to unlock) Continuity Door Lock Manual Switch Position OFF or UNLOCK No continuity Door Lock Manual Switch Position LOCK Continuity Door Lock Manual Switch Position OFF or LOCK No continuity Door Lock Manual Switch Position UNLOCK Continuity Passenger’s Door Key Lock and Unlock Switch Position OFF or UNLOCK (Door key No continuity free or turned to unlock) Passenger’s Door Key Lock and Unlock Switch Position LOCK (Door key turned to lock) Continuity BE–99 BODY ELECTRICAL SYSTEM – POWER DOOR LOCK CONTROL SYSTEM Tester connection to terminal number Condition 14 – Ground Passenger’s door courtesy switch position OFF (Door closed) No continuity 14– Ground Passenger’s door courtesy switch position ON (Door opened) Continuity 16 – Ground Constant Continuity Tester connection to terminal number Condition Specified value (Continuity) Specified value (Voltage) 1 – Ground Ignition switch position LOCK or ACC No voltage 1 – Ground Ignition switch position ON Battery positive voltage 8 – Ground Constant Battery positive voltage If circuit is as specified, inspect the door lock signal. If the circuit is not as specified, inspect the circuits connected to other parts. DOOR LOCK SIGNAL HINT: When the relay circuit is as specified, inspect the door lock signal. (a) Connect the connector to the relay. (b) Connect the positive (+) lead from the voltmeter to terminal 3 and the negative (–) lead to terminal 4. (c) Set the door lock manual switch to UNLOCK, check that the voltage rises from 0 volts to battery positive voltage for approximately 0.2 seconds. (d) Reverse the polarity of the voltmeter leads. (e) Set the door lock manual switch to LOCK, check that the voltage rises from 0 volts to battery positive voltage for approximately 0.2 seconds. If operation is not as specified, replace the relay. BE–100 BODY ELECTRICAL SYSTEM – SLIDING ROOF SYSTEM SLIDING ROOF SYSTEM DESCRIPTION Standby Operation • Current flows from the DOME fuse to terminal 12 of the sliding roof control relay (hereafter called relay). • When the ignition switch is ON, the current flows from the power main relay to terminal 6 of the relay. Operation 1. Limit Switch operation 2. OPEN operation When the switch on the ’OPEN’ side of the control switch is pushed, continuity is produced between terminal 1 of the relay and body ground. Then the relay operates, the current flows through terminal6 of the relay –i terminal 5 –i terminal 1 of the sliding roof motor – terminal 3 –) terminal 4 of the relay – terminal 11 – the body ground, and the motor starts to run in order to open the sliding roof. 3. CLOSE operation When the switch on the ”CLOSE” side of the control switch is pushed, continuity is produced between terminal 2 of the relay and body ground. Then the relay operates, the current flows through terminal6 of the relay –i terminal 4 –r terminal 3 of the sliding roof motor –i terminal 1 – terminal 5 of the relay –i terminal 11 –i the body ground, and the motor starts to run in order to close the sliding roof. Momentary Stop When the sliding roof reaches about 200 mm (7.87 in.) short of the fully closed position, the limit switch No.1 is turned from ON to OFF, so there is no continuity between terminal 4 of the relay and body ground. As a result, the sliding roof stops at that position. 4. TILT UP operation When the switch on the ”UP” side of the control switch is pushed, continuity is produced between terminal 3 of the relay and body ground. Then the relay operates, the current flows through terminal6 of the relay –terminal 4 – terminal 3 of the sliding roof motor –i terminal 1 –i terminal 5 of the relay – terminal 11 – the body ground, and the motor starts to run in order to tilt up the sliding roof. BE–101 BODY ELECTRICAL SYSTEM – SLIDING ROOF SYSTEM 5. TILT DOWN operation When the switch on the ”DOWN” side of the control switch is pushed, continuity is produced between terminal 7 of the relay and body ground. Then the relay operates, the current flows through terminal6 of the relay – terminal 5 –terminal 1 of the sliding roof motor –) terminal 3 –) terminal 4 of the relay – terminal 11 – the body ground, and the motor starts to. run in order to tilt down the sliding roof. PARTS LOCATION BE–102 BODY ELECTRICAL SYSTEM – SLIDING ROOF SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty. Trouble Parts name (See page) 1. ALT H –Fuse 2. P/W M – Fuse 3. Wire Harness (BE–4) (BE–4) 1. GAUGE Fuse 2. Ignition Switch 3. P/W M –Fuse 4. Power Main Relay 5. Sliding Roof Switch 6. Sliding Roof Control Relay 7. Sliding Roof Motor 8. Wire Harness (BE–4) (BE–14) (BE–4) (BE–89) (BE–103) (BE–104) (BE–103) Sliding roof system operates abnormally. 1. Sliding Roof Control Relay 2. Limit Switch 3. Sliding Roof Switch (BE–104) (BE–105) (BE–103) Sliding roof system stops operation half way. 1. Sliding Roof Control Relay (BE–104) 2. Limit Switch (BE–105) 3. Sliding Roof Switch (BE–103) 4. Sliding Roof Motor (BE–103) (Stones to foreign material trapped in motor assembly) ”Key–off Sliding Roof” operation does not operate. 1. DOME Fuse 2. GAUGE Fuse 3. Ignition Switch 4. Door Open Detection Switch 5. Wire Harness *1 Sliding roof system does not operate. *2 Sliding roof system does not operate. *1: Door– Lock does not operate. *2: Door– Lock is normal. (BE–4) (BE–4) (BE–14) (BE–94) BE–103 BODY ELECTRICAL SYSTEM – SLIDING ROOF SYSTEM SLIDING ROOF SWITCH INSPECTION INSPECT SLIDING ROOF SWITCH Continuity Inspect the switch continuity between terminals. Switch position Tester connection to terminal number Specified value 3–4 Continuity SLIDE CLOSE 4–6 Continuity TILT DOWN 2–4 Continuity SLIDE OPEN No continuity SLIDE OFF No continuity TILT OFF TILT UP 4–5 Continuity If continuity is not as specified, replace the switch. SLIDING ROOF MOTOR INSPECTION INSPECT SLIDING ROOF MOTOR Motor Operation (a) Connect the positive (+) lead from the battery to terminal 3 and the negative (–) lead to terminal 1, check that the motor turns to counterclockwise (moves of the close side). (b). Reverse the polarity, check that the motor turns to clockwise (moves to the open side). If operation is not as specified, replace the motor. Circuit Breaker operation (a) With the sliding roof in the fully opened position, hold the sliding roof switch in ”OPEN” position and check that there is a circuit breaker operation noise within 10 to 60 seconds. BE–104 BODY ELECTRICAL SYSTEM – SLIDING ROOF SYSTEM (b) With the sliding roof in fully opened position, hold the sliding roof switch in ”CLOSE” position and check that the sliding roof begins to close within 60 seconds. If operation is not as specified, replace the motor. SLIDING ROOF CONTROL RELAY INSPECTION INSPECT SLIDING ROOF CONTROL RELAY Circuit Disconnect the connector from the relay and inspect the connector on the wire harness side, as shown in the chart. Tester connection to terminal number Condition Specified value (Continuity) Sliding roof control switch position (SLIDE) OFF or CLOSE No continuity Sliding roof control switch position (SLIDE) OPEN Continuity Sliding roof control switch position (SLIDE) OFF or OPEN No continuity Sliding roof control switch position (SLIDE) CLOSE Continuity Sliding roof control switch position (TILT) OFF or DOWN No continuity Sliding roof control switch position (TILT) UP Continuity Constant No continuity Constant Continuity Constant No continuity Sliding roof control switch position (TILT) OFF or UP No continuity Sliding roof control switch position (TILT) DOWN Continuity No. 1 limit switch position OFF (Sliding roof tilted up or open approx. 200 mm (7.87in.)) No continuity No. 1 limit switch position ON (Except for conditions mentioned above) Continuity No. 2 limit switch position OFF (Sliding roof No continuity closed) No. 2 limit switch position ON (Sliding roof open) Continuity BE–105 BODY ELECTRICAL SYSTEM 11 – Ground – SLIDING ROOF SYSTEM Continuity Constant Tester connection to terminal number Specified value (Voltage) Condition 6 – Ground Ignition switch position LOCK or ACC *No voltage 6 – Ground Ignition switch position ON Battery positive voltage 12 – Ground Constant Battery positive voltage *: Exceptions: During 60 second period after ignition switch ON – OFF (ACC) or until driver or passenger door is opened after ignition switch ON –OFF (ACC). If circuit is as specified, replace the relay. LIMIT SWITCH INSPECTION INSPECT LIMIT SWITCH Continuity Inspect the switch continuity between terminals. Switch position Tester connection to terminal number No. 1 limit switch OFF (SW pin released) No. 1 limit switch ON (SW pin pushed in) No continuity 1–4 No.2 limit switch OFF (SW pin released) No.2 limit switch ON (SW pin pushed in) Specified value Continuity No continuity 2–4 Continuity If continuity is not as specified, replace the switch. DOOR OPEN DETECTION SWITCH See page BE–94. POWER MAIN RELAY See Power Main Relay on page BE–89. BE–106 BODY ELECTRICAL SYSTEM – POWER MIRROR CONTROL SYSTEM POWER MIRROR CONTROL SYSTEM PARTS LOCATION BE–107 BODY ELECTRICAL SYSTEM – POWER MIRROR CONTROL SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty. Parts name (see page) Mirror does not operate. 1. RADIO Fuse 2. Mirror Switch 3. Mirror Motor 4. Wire Harness (BE–4) (BE–108) (BE–109) Mirror operates abnormally. 1. Mirror Switch 2. Mirror Motor 3. Wire Harness (BE–108) (BE–109) Trouble BE–108 BODY ELECTRICAL SYSTEM – POWER MIRROR CONTROL SYSTEM MIRROR SWITCH INSPECTION INSPECT MIRROR SWITCH Continuity Inspect the switch continuity between terminals. LEFT SIDE Switch position Tester connection to terminal number OFF Specified vaIue No continuity Continuity DOWN Continuity LEFT Continuity RIGHT Continuity OFF Switch position Tester connection to terminal number Specified value No continuity OFF Continuity DOWN Continuity LEFT Continuity RIGHT Continuity RIGHT SIDE Switch position OFF Tester connection to terminal number Specified value No continuity Continuity DOWN Continuity LEFT Continuity RIGHT Continuity If continuity is not as specified, replace the switch. BE–109 BODY ELECTRICAL SYSTEM – POWER MIRROR CONTROL SYSTEM MIRROR MOTOR INSPECTION INSPECT MIRROR MOTOR Operation (a) Connect the positive (+) lead from the battery to terminal 3 and negative (–) lead to terminal 2, check that the mirror turns upward. (b) Reverse the polarity, check that the mirror turns to downward. (c) Connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 2, check that the mirror turns to left side. (d) Reverse the polarity, check that the mirror turns to right side. If operation is not as specified, replace the mirror. BE–110 BODY ELECTRICAL SYSTEM – POWER SEAT CONTROL SYSTEM POWER SEAT CONTROL SYSTEM PARTS LOCATION BE–111 BODY ELECTRICAL SYSTEM – POWER SEAT CONTROL SYSTEM TROUBLESHOOTING The table below will be useful for you in troubleshooting these electrical problems. The most likely causes of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and replace the part when it is found to be faulty. Trouble Parts name (See page) Power seat does not operate. (Door lock system does not operate) 1. ALT H –Fuse 2. Wire Harness 3. P/W M –Fuse (BE–4) Power seat does not operate. (Door lock system is normal) 1. P/W M –Fuse 2. Wire Harness 3. Power Seat Switch (BE–4) ”Slide operation” does not operate. ”Front Vertical Operation” does not operate. 1. Power Seat Switch 2. Wire Harness 3. Slide Motor 1. Power Seat Switch 2. Wire Harness 3. Front Vertical Motor ”Rear Vertical Operation” does not operate. 1. Power Seat Switch 2. Wire Harness 3. Rear Vertical Motor ”Reclining Operation” does not operate. 1. Power Seat Switch 2. Wire Harness 3. Reclining Motor (BE–4) (BE–112) (BE–112) (BE–113) (BE–112) (BE–113) (BE–112) (BE–114) (BE–112) (BE–115) BE–112 BODY ELECTRICAL SYSTEM – POWER SEAT CONTROL SYSTEM POWER SEAT SWITCH INSPECTION INSPECT POWER SEAT SWITCH Continuity Inspect the switch continuity between terminals. SLIDE SWITCH Switch position Tester connection to terminal number Specified value FRONT 5–10 8–9 Continuity OFF 5–9 8–9 Continuity BACK 5–9 8–10 Continuity FRONT VERTICAL SWITCH Switch position Tester connection to terminal number Specified value 10–12 4–11 Continuity OFF 4–11 4–12 Continuity DOWN 4–12 10–11 Continuity REAR VERTICAL SWITCH Switch position Tester connection to terminal number Specified value 2–10 6–7 Continuity OFF 2–7 6–7 Continuity DOWN 2–7 6–10 Continuity RECLINING SWITCH Switch position Tester connection to terminal number Specified value FORWARD 4–10 7–9 Continuity OFF 4–9 7–9 Continuity REAR 4–9 7–10 Continuity If continuity is not as specified, replace the switch. BE–113 BODY ELECTRICAL SYSTEM – POWER SEAT CONTROL SYSTEM SLIDE MOTOR INSPECTION INSPECT SLIDE MOTOR Operation (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the motor turns clockwise. (b) Reverse the polarity, check that the motor turns coun– terclockwise. If operation is not as specified, replace the motor. Circuit Breaker Operation (a) Connect the positive (+) lead from the battery to terminal 2 and negative (–) lead to terminal 1 on the slide motor connector, and move the seat front end position. (b) Continue to apply voltage, check that there is a circuit breaker operation noise within 3 to 60 seconds. (c) Reverse the polarity, check that the seat begins to move backwards within approximately 60 seconds. If operation is not as specified, replace the motor. FRONT VERTICAL MOTOR INSPECTION INSPECT FRONT VERTICAL MOTOR Operation (a) Connect the positive (+) lead from the battery to terminal 1 and the negative (–) lead to terminal 2, check that the motor turns clockwise. (b) Reverse the polarity, check that the motor turns coun– terclockwise. If operation is not as specified, replace the motor. PTC Thermistor Operation / Driver’s Seat (a) Connect the positive (+) lead from the battery to terminal 1, the positive (+) lead from the ammeter to terminal 2 and the negative (–) lead to battery nega– tive (–) terminal, and move the front edge of seat cushion to the highest position. (b) Continue to apply voltage, check the current changes to less than 1 ampere with 4 to 90 seconds. BE–114 BODY ELECTRICAL SYSTEM – POWER SEAT CONTROL SYSTEM (c) Disconnect the leads from terminals. (d) Approximately 60 seconds later, connect the positive (+) lead from battery to terminal 2 and the negative (–) lead to terminal 1, check that the seat cushion begins to descend. If operation is not as specified, replace the motor. REAR VERTICAL MOTOR INSPECTION INSPECT REAR VERTICAL MOTOR Operation (a) Connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 2, check that the motor turns clockwise. (b) Reverse the polarity, check that the motor turns coun– terclockwise. If operation is not as specified, replace the motor. PTC Thermistor Operation / Driver’s seat (a) Connect the positive (+) lead from the battery to terminal 1, the positive (+) lead from the ammeter to terminal 2 and the negative (–) lead to battery nega– tive (–) terminal, and move the rear edge of seat cushion to the highest position. b) Continue to apply voltage, check the current changes to less than 1 ampere with 4 to 90 seconds. (c) Disconnect the leads from terminals. (d) Approximately 60 seconds later, connect the positive (+) lead from battery to terminal 2 and the negative (–) lead to terminal 1, check that the seat cushion begins to descend. If operation is not as specified, replace the motor. BE–115 BODY ELECTRICAL SYSTEM – POWER SEAT CONTROL SYSTEM RECLINING MOTOR INSPECTION (Except 2–door) INSPECT RECLINING MOTOR Operation (a) Connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 2, check that the motor turns clockwise. (b) Reverse the polarity, check that the motor turns coun– terclockwise. If operation is not as specified, replace the motor. PTC Thermistor Operation/ Driver’s Seat (a) Connect the positive (+) lead from the battery to terminal 2, the positive (+) lead from the ammeter to terminal 1 and the negative lead to battery negative (–) terminal, and recline the seat back to the most forward position. (b) Continue to apply voltage , check the current change to less than 1 ampere with 4 to 90 seconds. (c) Disconnect the lead from terminals. (d) Approximately 60 seconds later, connect the positive (+) lead from battery to terminal 1 and the negative (–) lead to terminal 2, check that the seat back starts to fall backwards. If operation is not as specified, replace the motor. BE–116 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM AUDIO SYSTEM SYSTEM DESCRIPTION 1. RADIO WAVE BAND The radio wave bands used in radio broadcasting are as follows: Frequency 30 kHz 300kHz 3 MHz Designation 30 MHz 300 MHz VHF Radio wave Modulation method Amplitude modulation Frequency modulation LF: low Frequency MF: Medium Frequency HF: High Frequency VHF: Very High Frequency 2. SERVICE AREA There are great differences in the size of the service area for AM, FM monaural, and FM stereo broadcasts cannot be received even though AM comes in very clearly. Not only does FM stereo have the smallest service area, but it also picks up static and other types of interference (”noise”) easily. BE–117 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM 3. RECEPTION PROBLEMS Besides the problem of static, there are also the prob– lems called ”fading”, ”rnultipath” and ”fade out”. These problems are caused not by electrical noise but by the nature of the radio waves themselves. Fading Besides electrical interference, AM broadcasts are also susceptible to other types of interference, espe– cially at night. This is because AM radio waves bounce off the ionosphere at night. These radio waves then interfere with the signals from the same trans– mitter that reach the vehicle’s antenna directly. This type of interference is called ”fading”. Multipath One type of interference caused by the bouncing of radio waves off of obstructions is called ”multipath”. Multipath occurs when a signal from the broadcast transmitter antenna bounces off buildings and moun– tains and interferes with the signal that is received directly Fade Out Because FM radio waves are of higher frequencies than AM radio waves, they bounce off buildings, mou– ntains, and other obstructions. For this reason, FM signals often seem to gradually disappear or fade away as the vehicle goes behind a building or other obstruction. This is called ”fade out”. BE–118 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM 4. COMPACT DISC PLAYER Compact Disc (hereafter called ”CD”) Players use a laser beam pick–up to read the digital signals recor– ded on the CD and reproduce analog signals of the music, etc. There are 4.7 in. (12 cm) and 3.2 in. (8 cm) discs in the CD player. HINT: Never attempt to disassemble or oil any part of the player unit. Do not insert any object other than a disc into the magazine. NOTICE: CD players use an invisible laser beam which could cause hazardous radiation exposure. Be sure to operate the player correctly as instructed. MAINTENANCE Tape Player/Head Cleaning (a) Raise the cassette door with your finger. Next using a pencil or like object, push in the guide. (b) Using a cleaning pen or cotton applicator soaked in cleaner, clean the head surface, punch rollers and capstans. CD Player/Disc Cleaning If the disc gets dirty, clean the disc by wiping the surfaces from the center to outside in the radial direc– tions with a soft cloth. NOTICE: Do not use a conventional record cleaner or anti–static preservative. BE–119 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM ANTI–THEFT SYSTEM HINT: The words ”ANTI–THEFT SYSTEM” are dis– played on the cassette tape slot cover. For operation instructions for the anti–theft system, please consult the audio system section in the Owner’s Manual (hereafter called O/M). 1. SETTING SYSTEM The system is in operation once the customer has pushed the required buttons and entered the custom– er–selected 3–digit ID number. (Refer to the O/M section, ”Setting the anti–theft system”) HINT: • When the audio system is shipped the ID number has not been input, so the anti–theft system is not in operation. • If the ID number has not been input, the audio system remains the same as a normal audio system. 2. ANTI–THEFT SYSTEM OPERATION If the normal electrical power source (connector or battery terminal) is cut off, the audio system becomes inoperable, even if the power supply resumes. 3. CANCELLING SYSTEM The ID number chosen by the customer is input to cancel the anti–theft system. (Refer to the O/M section, ’if the system is activated”) HINT: To change or cancel the ID number, please refer to the 0/M section ”Cancelling the system”. BE–120 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM PARTS LOCATION BE–121 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM BE–122 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM TROUBLESHOOTING NOTICE: When replacing the internal mechanism (ECU part) of the audio system, be careful that no part of your body or clothing comes in contact with the terminals of the leads from the IC etc. of the replacement part (spare part), HINT: This inspection procedure is a simple troubleshooting which should be carried out on the vehicle during system operation and was prepared on the assumption of system component troubles (except for the wires and connectors, etc.). Always inspect the trouble taking the following items into consideration. • Open or short circuit of the wire harness • Connector or terminal connection fault Problem Radio not operating when power switch turned to ”ON’. Display indicates when power switch turned to ’ON’, but no sound (including ’noise’) is produced. Radio Noise present, but AM–FM not operating. Any speaker does not work. Reception poor. Sound quality poor. Preset memory disappears. Cassette tape cannot be inserted. Cassette tape inserts, but no power Power coming in, but tape player not operating. Tape player Any speaker does not work. Sound quality poor. Tape jammed, malfunction with tape speed or auto–reverse Cassette tape will not eject. CD cannot be inserted. C D inserts, but no power Power coming in, but CD player not operating. CD Player Sound jumps. Sound quality poor (Volume faint). Any speaker does not work. CD will not eject. Antenna Antenna–related. Noise produced by vibration or shock white driving. Noise Noise produced when engine starts. The term”AM” includes LW, MW and SW, and the term ”FW” includes UKW. No. BE–123 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM HOW TO USE DIAGNOSTIC CHART Reference: Radio NO POWER COMING IN Check if RADIO fuse is OK? Replace fuse Yes Check if DOME fuse is OK? Replace fuse Yes Is ACC applied to radio? ACC wire harness faulty Yes Check if GND (Wire harness side) to radio is OK? GND wire harness faulty Yes Radio faulty 1 : Phenomenon : Problem 2 : Check item 3 : Trouble part or disposal BE–124 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Troubleshooting for ANTI–THEFT SYSTEM Turn Ignition key from LOCK position to ACC position. Display A: I D Number is set. ”SEC” display disappears after second. Display E: ANTI–THEFT SYSTEM operation condition. (ID number input error 10 times or more.) Display B. Radio switch ON. Yes Display6 Display D Refer to each malfunction item. Normal operation. Take to designated radio service station. Radio switch ON. Normal operation. Cancel ID number, refer to each malfunction item. ANTI–THEFT SYSTEM operation condition. (ID number input error 9 times or less.) Input ID number to cancel ANTI–THEFT SYSTEM, and check display. Display A –B Display B Display E Display C –+ A Radio switch ON. Refer to each mal– function item. Take to designated radio service station. ANTI–THEFT SYSTEM not cancelled. (ID number input error 10 times or less.) Display D ANTI–THEFT SYSTEM cancelled. Check audio system again. Normal operation. Cancel I D number, refer to each malfunction item. (Liquid Crystal Display (LCD) or VFD for Audio System) HINT; • Refer to Owner’s Manual for operation details of ANTI–THEFT SYSTEM. • When the ID number has been cancelled, reset the same number after completing the operation, or inform the customer that it has been cancelled. BE–125 BODY ELECTRICAL SYSTEM Radio – AUDIO SYSTEM RADIO NOT OPERATING WHEN POWER SWITCH TURNED TO ’ON’ Check if RADIO fuse is OK? Replace fuse. Is ACC applied to radio ? ACC wire harness faulty. Yes Check if DOME fuse is OK? Replace fuse. Is +B applied to radio? + B wire harness faulty. Yes Check if GND (wire harness side) to radio is OK? Radio assembly faulty. G N D .faulty. BE–126 BODY ELECTRICAL SYSTEM Is tape player operating normally? – AUDIO SYSTEM Yes Radio assembly faulty. Check if RADIO fuse is OK? Replace fuse. Is ACC applied to radio? ACC wire harness faulty. Yes Check if DOME fuse is OK? Replace fuse. Is +B applied to radio? + B wire harness faulty. Yes Check if GND (wire harness side) to radio is OK? Radio assembly faulty. GND faulty. BE–127 BODY ELECTRICAL SYSTEM Is tape player operating normally? – AUDIO SYSTEM Yes Radio assembly faulty. Check if RADIO fuse is OK? Replace fuse. Is ACC applied to power amplifier? ACC wire harness faulty. Yes Check if DOME fuse is OK? Replace fuse. Is + B applied to power amplifier? + B wire harness faulty. Yes Check if GND (wire harness side) to power amplier is OK? GND faulty. Is ACC applied to radio assembly? Power amplifier faulty. Yes Is + B applied to radio assembly? Power amplifier faulty. Yes Check if GND (wire harness side) to radio assembly is OK? Radio assembly faulty. GND faulty. BE–128 BODY ELECTRICAL SYSTEM Radio – AUDIO SYSTEM DISPLAY INDICATES WHEN POWER SWITCH TURNED TO ’ON’, BUT NO SOUND (INCLUDING ’NOISE’) IS PRODUCED Check if RADIO fuse is 0K? Replace fuse. Is ACC applied to radio? ACC wire harness faulty. Yes Check if DOME fuse is OK? Replace fuse. Is +B applied to radio? + B wire harness faulty. Yes Check if GND (wire harness side) to radio is OK? GND faulty. Is there continuity in speaker wire harness? Speaker wire harness faulty. Yes Temporarily install another speaker. Yes If radio side faulty Go to No. 15 Radio faulty. Speaker faulty. BE–129 BODY ELECTRICAL SYSTEM Is tape player operating normally? – AUDIO SYSTEM Yes Radio faulty. Check if RADIO fuse is OK? Replace fuse. Is ACC applied to radio? ACC wire harness faulty. Yes Check if DOME fuse is OK? Replace fuse. Is + B applied to radio? + B wire harness faulty. Yes Check if GND (wire harness side) to radio is OK? GND faulty. Is there continuity in speaker wire harness? Speaker wire harness faulty. Yes Yes Temporarily install another speaker. If radio side faulty Go to No. 15 Radio faulty. Speaker faulty. BE–130 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Yes Is tape player operating normally? Is power for the antenna being output from the tape player? Yes Yes Is power for the antenna being output from the power amplifier? Radio assembly faulty. If power amplifier side faulty Power amplifier faulty. Go to No. 15 Check if RADIO fuse is OK? Replace fuse. Is ACC applied to power amplifier. ACC wire harness faulty. Yes Check if DOME fuse is OK? Replace fuse. Is + B applied to power amplifier. +B wire harness faulty. Yes Check if GNO (wire harness side) to power amplifier is OK? GND faulty. Is ACC applied to radio assembly? Power amplifier faulty. Yes Is + B applied to radio assembly? Power amplifier faulty. Yes Check if G N D (wire harness side) to radio assembly is OK? CONTINUED ON NEXT PAGE G N D faulty. BE–131 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE !s there continuity in speaker wire harness? Speaker wire harness faulty. Yes Temporarily install another speaker. Functions OK? Yes Hissing sound from speaker? Speaker faulty. Power amplifier faulty. Recheck system after repair. Yes Radio assembly faulty. Recheck system after repair. Radio NOISE PRESENT, BUT AM–FM NOT OPERATING Go to No. 15 if radio side faulty Radio Radio faulty. ANY SPEAKER DOES NOT WORK Is hiss produced by non–functioning speaker? Yes Radio faulty. Speaker wire harness faulty. !s there continuity in speaker wire harness? Yes Temporarily install another speaker. Functions OK? Radio faulty. Yes Speaker faulty. BE–132 BODY ELECTRICAL SYSTEM Is tape player operating normally? – AUDIO SYSTEM Yes Yes Radio assembly faulty. Is hiss produced by non–functioning speaker? Radio assembly faulty. Is there continuity in speaker wire harness? Speaker wire harness faulty. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. Radio assembly faulty. Yes Is tape player operating normally? Is hiss produced by non–functioning speaker? Yes Radio assembly faulty. Radio assembly faulty. Recheck system after repair. Speaker wire harness faulty. Is there continuity in speaker wire harness? Yes Temporarily install another speaker? Functions OK? Power amplifier faulty. Recheck system after repair. Yes Speaker faulty. BE–133 BODY ELECTRICAL SYSTEM Radio – AUDIO SYSTEM EITHER AM OR FM DOES NOT WORK, RECEPTION POOR (VOLUME FAINT), FEW PRESET TUNING BANDS Problem with radio wave signals or location? Yes Are both AM or FM defective? Poor signals, poor location. Radio faulty. Yes Is power for the antenna being output from the radio? Yes Go to No. 15 Temporarily install another speaker. Functions OK? Yes Speaker faulty. Radio faulty. Problem with radio wave signals or location? Are both AM or FM defective? Yes Is power for the antenna being output from the radio assembly? Yes Go to No. 15 CONTINUED ON NEXT PAGE Yes Poor signals, poor location. Radio assembly faulty. BE–134 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE Is tape player operating normally? Temporarily install another speaker. Functions OK? Yes Yes Radio assembly faulty. Speaker faulty. Radio assembly faulty. Problem with radio wave signals or location? Yes Are both AM and FM defective? Poor signals, poor location. Radio assembly faulty. Yes Is power for the antenna being output from the radio assembly? I Yes Go to No. 15 Is tape player operating normally? Temporarily install another speaker. Functions OK? Hissing sound from speaker? ¿Yes Radio assembly faulty. Recheck system after repair. Yes Yes Radio assembly faulty. Speaker faulty. Power amplifier faulty. Recheck system after repair. BE–135 BODY ELECTRICAL SYSTEM Radio – AUDIO SYSTEM SOUND QUALITY POOR Is sound quality always bed? Is sound quality bad in certain area only? Yes Poor signals, poor location. Yes Radio faulty. Install properly. is speaker properly installed? Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. Radio faulty. Is power for the antenna being output from the radio? Yes If radio side faulty Go to No. 15 Is sound quality always bad? Is sound quality bad in certain area only? Yes Poor signals, poor location. Yes Radio assembly faulty. Is tape player operating normally? Yes Is power for the antenna being output from the radio assembly? Yes If radio side faulty Go to No. 15 Is speaker properly installed? Radio assembly faulty. Install property. Yes CONTINUED ON NEXT PAGE Radio assembly faulty. BE–136 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE Yes Speaker faulty. Temporarily install another speaker. Functions OK? Radio assembly faulty. Is sound quality bad in certain areas only? Is sound quality always bad? Yes Poor signals, poor location. Yes Yes Is tape player operating normally? Is tape player operating normally? Yes Radio assembly or power amplifier faulty. Radio assembly faulty. Is power for the antenna being output from the radio assembly? Radio assembly faulty. Yes Is power for the antenna being output from the power amplifier? Is speaker properly installed? Install properly. Yes Temporarily install another speaker. Functions OK? Radio assembly or power amplifier faulty. Recheck system after repair. Yes Speaker faulty. Power amplifier faulty. BE–137 BODY ELECTRICAL SYSTEM Radio – AUDIO SYSTEM PRESET MEMORY DISAPPEARS Check if DOME fuse is OK? Replace fuse. Is + B applied to radio? + B wire harness faulty. Yes Check if GND (wire harness side) to radio? GND faulty. Radio faulty. Can cassette tape be inserted in tape player? Yes Radio assembly faulty. Check if DOME fuse is OK? Replace fuse. Is + B applied to radio assembly? +B wire harness faulty. Yes Check if GND (wire harness side) to radio? Radio assembly faulty. GND faulty. BE–138 BODY ELECTRICAL SYSTEM Can cassette tape be inserted in tape player? – AUDIO SYSTEM Yes Radio assembly faulty. Check if DOME fuse is OK? Replace fuse. Is + B applied to power amplifier? + B wire harness faulty. Yes Check if GND (wire harness side) to power amplifier? GND faulty. Is + B applied to radio assembly? Power amplifier faulty. Yes Check if GND (wire harness side) to radio assembly? Radio assembly faulty. Power amplifier faulty. BE–139 BODY ELECTRICAL SYSTEM Tape Player – AUDIO SYSTEM CASSETTE TAPE CANNOT BE INSERTED Is there a foreign object inside tape player? Is auto search button of radio operating normally? Yes Yes Remove foreign object. Radio assembly faulty. Check if DOME fuse is OK? Replace fuse. Is +B applied to radio assembly? +B wire harness faulty. Yes Check if GND (wire harness side) to radio assembly? GND faulty. Radio assembly faulty. Is there a foreign object inside tape player? Is auto search button radio operating normally? Check if DOME fuse is OK? Yes Yes Remove foreign object. Radio assembly faulty. Replace fuse. OK CONTINUED ON NEXT PAGE BE–140 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE + B wire harness faulty. Is + B applied to power amplifier? Yes Check if GND (wire harness side) to power amplifier is OK? GND faulty. Is + B applied to radio assembly Power amplifier faulty. Yes Power amplifier faulty. Check if GND (wire harness side) to radio assembly is OK? Radio assembly faulty. CASSETTE TAPE INSERTS, BUT NO POWER ¿¿ Tape Player Yes Is radio operating normally? Radio assembly faulty. Check if RADIO fuse is OK? Replace fuse. Is ACC applied to radio assembly? ACC wire harness faulty. Yes Check if DOME fuse is OK? Is + B applied to radio assembly? Yes Radio assembly faulty. NG No Replace fuse. + B wire harness faulty. BE–141 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Yes Is radio operating normal? Radio assembly faulty. Check if RADIO fuse is OK? Replace fuse. Is ACC applied to power amplifier? ACC wire harness faulty. Yes Check if DOME fuse is OK? Replace fuse. Is + B applied to power amplifier? + B wire harness faulty. Yes Is ACC applied to radio assembly? Yes Radio assembly faulty. Power amplifier faulty. BE–142 BODY ELECTRICAL SYSTEM Tape Player – AUDIO SYSTEM POWER COMING IN, BUT TAPE PLAYER NOT OPERATING Functions OK if different cassette tape inserted? Is radio operating normally? Yes Yes Is there continuity in speaker wire harness? Cassette tape faulty. Radio assembly faulty. Speaker wire harness faulty. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. Radio assembly faulty. Function 4K if different cassette tape inserted? Is radio operating normally? Is there continuity in speaker wire harness? Yes CONTINUED ON NEXT PAGE Yes Yes Cassette tape faulty. Radio assembly faulty. Speaker wire harness faulty. BE–143 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE Temporarily install another speaker. Function OK? Yes Hissing sound from speaker? Speaker faulty. Power amplifier faulty. Recheck system after repair. Yes Radio assembly faulty. Recheck system after repair. Tape Player EITHER SPEAKER DOES NOT WORK Is radio operating normally? Is hiss produces by non–functioning speaker. Yes Yes Radio assembly faulty. Is there continuity in speaker wire harness? Temporarily install another speaker. Functions OK? Radio assembly faulty. Radio assembly faulty. Speaker wire harness faulty. Yes Speaker faulty. BE–144 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Yes Is radio operating normally? Is hiss produced by non–functioning speaker? Yes Radio assembly faulty. Radio assembly faulty. Recheck system after repair. Speaker wire harness faulty. Is there continuity in speaker wire harness? Yes Yes Temporarily install another speaker. Function OK? Speaker faulty. Radio assembly or power amplifier faulty. Tape Player SOUND QUALITY POOR (VOLUME FAINT) Functions OK if different cassette tape inserted? Operates normally after cleaning the heads? Yes Yes Cassette tape faulty. Head dirty. Yes Is radio operating normally? Radio assembly faulty. Is speaker properly installed? Yes CONTINUED ON NEXT PAGE Install properly. BE–145 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE Temporarily install another speaker. Function OK? Yes Speaker faulty. Radio assembly faulty. Functions OK different cassette tape inserted? Operates normally after cleaning the heads? Is radio operating normally? Yes Yes Yes Is speaker properly installed? Cassette tape faulty. Head dirty. Radio assembly faulty. Install properly. Yes Yes Temporarily install another speaker. Functions OK? Radio assembly faulty, Speaker faulty. BE–146 BODY ELECTRICAL SYSTEM Tape Player – AUDIO SYSTEM TAPE JAMMED MALFUNCTION WITH TAPE SPEED OR AUTO–REVERSE Function OK if different tape (less than 120 mins.) is inserted? Is there a foreign abject inside tape player? Operates normally after cleaning the heads? Yes Yes Yes Cassette tape faulty. Remove foreign object. Head dirty. Radio assembly faulty. Tape Player CASETTE TAPE WILL NOT EJECT Is tape player operating normally? Cassette tape jammed. Yes Is auto search button of radio operating normally? Yes Radio assembly faulty. Check if DOME fuse is OK? Replace fuse. Is + B applied to radio assembly? + B wire harness faulty. Yes Radio assembly faulty? BE–147 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Cassette tape jammed. Is tape player operating normally? Yes Yes Is auto search button of radio operating normally? Radio assembly faulty. Check if DOME fuse is OK? Replace fuse. !s + B applied to power amplifier? + B wire harness faulty. Yes Power amplifier faulty. Is +B applied to radio assembly? Yes Radio assembly faulty. CD Player CD CANNOT BE INSERTED Yes Is CD already inserted? Is auto search button of radio operating normally? Yes Eject CD. Is + B applied to CD player? Yes Check if GND wire harness side to CD player is OK? CD player faulty. Check if DOME fuse is OK? Replace fuse. OK CONTINUED ON NEXT PAGE Radio assembly faulty. BE–148 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE Is +B applied to power amplifier? +B wire harness faulty. Yes Check if GND (wire harness side) to radio assembly is OK? Radio assembly faulty. CD Player CD INSERTS, BUT NO POWER Yes Is radio operating normally? Is ACC applied to CD player? Radio assembly faulty. Yes CD player faulty. Check if RADIO fuse is OK? Replace fuse. Is ACC applied to power amplifier? ACC wire harness faulty. Yes Is ACC applied to radio assembly? Power amplifier faulty. Yes Radio assembly faulty. CD Player POWER COMING IN, BUT CD PLAYER NOT OPERATING Is CD inserted correct side up? Insert correctly. Yes Yes function OK if different CD inserted? Is radio operating normally? CD faulty. Yes Is temperature inside cabin hot? Yes Protective circuit in operation. CONTINUED ON NEXT PAGE CONTINUED ON NEXT PAGE BE–149 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE Yes CONTINUED FROM PREVIOUS PAGE Formation of condensation due to temp. change. Has sudden temperature change occurred inside cabin? CD player faulty. Speaker wire harness faulty. Is there continuity in speaker wire harness? Yes Yes Temporarily install another speaker, Functions OK? Speaker faulty. Hissing sound from speaker? Power amplifier faulty. Recheck system after repair. Yes Radio assembly faulty. Recheck system after repair. CD Player SOUND JUMPS Yes Does sound jump only during strong vibration? Jumping caused by vibration. Is CD player properly installed? Install properly. Yes Functions OK if different CD inserted? Has sudden temperature change occurred inside cabin? CD player faulty. Yes Yes CD faulty. Formation of condensation due to temp. change. BE–150 BODY ELECTRICAL SYSTEM CD Player – AUDIO SYSTEM SOUND QUALITY POOR (VOLUME FAINT) Functions OK if different CD inserted? Yes Yes Is radio operating normally? Is speaker properly installed? CD faulty. CD player faulty. Install properly. Yes Temporarily install another speaker. Functions OK? Yes Speaker faulty. Radio assembly or CD player or Power amplifier faulty. CD Player EITHER SPEAKER DOES NOT WORK Is radio operating normally? Is hiss produced by non–functioning speaker? Yes Yes Is there continuity in speaker wire harness? C D player faulty. Radio assembly faulty. Recheck system after repair. Speaker wire harness faulty. Yes Temporarily install another speaker. Function OK. Power amplifier faulty. Recheck system after repair. Yes Speaker faulty. BE–151 BODY ELECTRICAL SYSTEM CD Player – AUDIO SYSTEM CD WILL NOT EJECT Is auto search button of radio operating normally? Yes Is + B applied to CD player? Radio assembly faulty. Yes CD player faulty. Check if DOME fuse is OK? Replace fuse. Is +B applied to power amplifier? + B wire harness faulty. Yes Is + B applied to radio assembly? Power amplifier faulty. Yes Radio assembly faulty. Antenna ANTENNA – RELATED Antenna w/o Motor Type Is antenna extended? Extend fully. Yes Temporarily install another antenna, Functions OK? Radio side faulty. Yes Antenna faulty. BE–152 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM Motor Antenna Type Does antenna extend when radio switched ON? Yes Temporarily install another antenna. Functions OK? Yes Motor antenna faulty. Radio side faulty. Inspect antenna motor. Antenna motor faulty. Inspect antenna motor control relay. (Relay circuit) Relay faulty. Yes Is power related to the antenna being input to the antenna motor control relay? Check continuity between antenna motor control relay and radio. Relay circuit faulty. Wire harness faulty. Radio side faulty. Motor Antenna and Glass Printed Antenna Type Yes Does antenna extend when radio switched ON? Inspect glass printed antenna. Glass printed antenna faulty. Temporarily install another antenna. Functions OK? Radio side faulty. CONTINUED ON NEXT PAGE Yes Motor antenna faulty. BE–153 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM CONTINUED FROM PREVIOUS PAGE Inspect antenna motor. Antenna motor faulty. Inspect antenna motor control relay. (Relay circuit) Relay faulty. Is power related to the antenna being input to the antenna motor control relay? Yes Relay circuit faulty. Wire harness faulty. Check continuity between antenna motor control relay and radio. Radio side faulty. Noise NOISE PRODUCED BY VIBRATION OR SHOCK WHILE DRIVING Install properly. Is speaker properly installed? Yes Is each system correctly installed? Yes Yes With vehicle stopped lightly tap each system. Is noise produced? Noise produced by static electricity accumulating in the vehicle body. Each system faulty. BE–154 BODY ELECTRICAL SYSTEM Noise – NOISE PRODUCED WHEN ENGINE STARTS Whistling noise which becomes high–pitched when accelerator strongly depressed, disappears shortly after engine stops. Whining noise occurs when A/C is operating. Scratching noise occurs during sudden acceleration, driving on rough roads or when ignition switch is turned on. Clicking sound heard when horn button is pressed, then released. Whirring /grating sound when pushed continuously. Murmuring sound, stops when engine stops. Tick–tock noise occurs in co–ordination with blinking of flasher. Noise occurs during window washer operation. Scratching noise occurs while engine is running, continues a while even after engine stops. Scraping noise in time with wiper beat. Other type of noise. AUDIO SYSTEM Yes Yes Yes Yes Yes Yes Yes Yes Yes Generator noise. A/C noise. Fuel gauge noise. Horn noise. Ignition noise. Turn signal noise. Washer noise. Engine coolant temp. gauge noise. Wiper noise. BE–155 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM MOTOR ANTENNA REMOVAL AND INSTALLATION 1. REMOVE MOTOR ANTENNA (a) Remove the antenna nut. (b) Remove the RH side cover. (c) Disconnect the motor antenna connector. (d) Remove the nut and the motor antenna assembly. (e) Disconnect the antenna cord. (f) Remove the drain hose. 2. INSTALL MOTOR ANTENNA (a) Connect the motor antenna connector and the anten– na cord. (b) Install the antenna nut. (c) Install the nut. (d) Connect the drain hose. ANTENNA ROD REMOVAL AND INSTALLATION 1. REMOVE ANTENNA ROD HINT: Perform this operation with the battery nega– tive (–) cable connected to the battery terminal. (a) Turn the ignition switch to ”LOCK” position. (b) Remove the antenna nut. (c) Press the ’AM’ or ”FM” button on the radio receiver, and simultaneously turn the ignition switch to ”ACC” position. HINT: • The rod will extend fully and be released from the motor antenna. • After removing the antenna rod, leave the igni– tion switch at ”ACC”. NOTICE: To prevent body damage when the antenna rod Is released, hold the rod while It comes out. BE–156 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM 2. INSTALL ANTENNA ROD (a) Insert the cable of the rod until it reaches the bottom. HINT: • When inserting the cable, the teeth on the cable must face toward the rear of the vehicle. • Insert the cable approx. 400 mm (15.7 in.). (b) Wind the cable to retract the rod by turning the ignition switch to ”LOCK” position. HINT: • If the ignition switch is already in ”LOCK” posi– tion, perform step 1 (c) first, then turn the ignition switch to ”ACC” position. • In case the cable is not wound, twist it, as shown in the illustration. • Even if the rod has not retracted fully, install the antenna nut and inspect the antenna rod opera– tion. It will finally retract fully. (c) Inspect the antenna rod operation by pushing the radio wave band select buttons. MOTOR ANTENNA INSPECTION 1. INSPECT MOTOR ANTENNA Circuit Disconnect the motor antenna connector from the body wire harness and inspect the connector on body wire harness side, as shown. Tester connection to terminal number Condition Specified value (Voltage) 3 – Ground Battery positive voltage Constant Ignition switch ACC or ON and radio switch No voltage ON Others 3 – Ground Ignition switch ACC or ON and radio switch Battery positive voltage ON AM or FM (87.9 – 96.0 MHz) 4 – Ground Ignition switch ACC or ON Radio switch OFF 4 – Ground Ignition switch ACC or ON Radio switch ON Battery positive voltage 5 – Ground Ignition switch position ACC or LOCK No voltage 5 – Ground Ignition switch position ON Battery positive voltage 6 – Ground Ignition switch position LOCK No voltage 6 – Ground Ignition switch position ACC or ON Battery positive voltage 2 – Ground No voltage BE–157 BODY ELECTRICAL SYSTEM Tester connection to terminal number 1 – Ground Condition Constant – AUDIO SYSTEM Specified value (Continuity) Continuity If circuit is not as specified, inspect radio or wire harness. If circuit is as specified, replace motor antenna. 2. INSPECT ANTENNA MOTOR (a) Connect the positive (+) lead from the battery to terminal 1 and negative (–) lead to terminal 4. (b) Check that the motor turns (moves upward). NOTICE: These tests must be performed quickly (within 3 – 5 seconds) to prevent the coil from burning out. (c) Then, reverse the polarity, check that the motor turns the opposite way (moves downward). NOTICE: These tests must be performed quickly (within 3 – 5 seconds) to prevent the coil from burning out. If operation is not as specified, replace the motor. BE–158 BODY ELECTRICAL SYSTEM – AUDIO SYSTEM 3. INSPECT ANTENNA MOTOR CONTROL RELAY Relay Circuit Disconnect the connector from the relay and inspect the connector on wire harness side, as shown in the chart. Tester connection to terminal number 1–4 2 – Ground Tester connection to terminal number 3 – Ground Condition Specified value (Continuity) Constant Continuity Constant Continuity Condition Specified value (Voltage) 5 – Ground Constant Ignition switch position LOCK Battery positive voltage No voltage 5 – Ground Ignition switch position ACC or ON Battery positive voltage 6 – Ground Ignition switch position LOCK No voltage 6 – Ground Ignition switch position ACC or ON Radio switch and cassette OFF No voltage 6 – Ground Ignition switch position ACC or ON Radio switch or cassette ON Battery positive voltage 8 – Ground Ignition switch position LOCK No voltage 8 – Ground Ignition switch position ACC or ON Radio switch OFF or casette ON No voltage 8 – Ground Ignition switch position ACC or ON Radio switch ON and casette OFF Battery positive voltage 9 – Ground Ignition switch position LOCK or ACC No voltage 9 – Ground Ignition switch position ON Battery positive voltage If circuit is as specified, replace the relay. GLASS PRINTED ANTENNA INSPECTION 1. INSPECT GLASS PRINTED ANTENNA (Use same procedure as for ”INSPECT DEFOGGER WIRES” on page BE–80.) 2. REPAIR GLASS PRINTED ANTENNA (Use same procedure as for ” REPAIR DEFOGGER WIRES” on page BE–80.) BE–159 BODY ELECTRICAL SYSTEM – CLOCK CLOCK TROUBLESHOOTING HINT: Troubleshoot the clock according to the table below. Clock will not operate Clock loses or gains time ± 1.5 seconds/day CLOCK WILL NOT OPERATE (a) Check that the battery positive voltage is 10 – 16 V. If voltage is not as specified, replace the battery. (b) Check that the DOME fuse is not blown. If the fuse is blown, replace the fuse and check for short. (c) Troubleshoot the clock as follows. HINT: Inspect the connector on the wire harness side. BE–160 BODY ELECTRICAL SYSTEM – CLOCK Open or short circuit in wire harness between terminal + B and DOME fuse. Is there battery positive voltage between terminal + B and body ground? Yes Is there continuity between terminal GND and body ground? Open circuit in wire harness between terminal GND and body ground. Yes Replay clock. CLOCK LOSES OR GAINS TIME (a) Check that the battery positive voltage is 10 – 16 V. If voltage is not as specified, replace the battery. (b) Inspect the error of the clock. Allowable error (per day): ± 1.5 seconds If the error exceeds the allowable error, replace the clock. (c) Check that the clock adjusting button is sticking in posi– tion and has failed to return. If the button is not returned, repair or replace the clock. (d) Troubleshoot the clock as follows. HINT: Inspect the connector on the wire harness side. Is there 10 – 16 V between terminal +B and body ground? Yes Adjust or replace clock. Below 10 V Locate cause and repair, or recharge battery. BE–161 BODY ELECTRICAL SYSTEM – MEMO – – CLOCK BE–162 BODY ELECTRICAL SYSTEM –MEMO – – CLOCK BE–163 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM BE–164 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DESCRIPTION The cruise control system is standard, which is convenient when driving continuously at a constant speed. The cruise control ECU controls all cruise control functions. A diagnosis function is built in. In the unlikely event of a malfunction in the system, the problem area is detected by the cruise control ECU and it causes the power indicator light on the combination meter to blink, warning the driver that there is an abnormality as well as storing a malfunction code in the ECU memory for the service technician to retrieve. PARTS LOCATION BE–165 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING Perform troubleshooting in accordance with the procedure on the following page. 1. CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in as much detail as possible about the problem. 2. CHECK AND CLEAR THE DIAGNOSTIC TROUBLE CODES (PRECHECK) When there is a problem with the cruise control being canceled or failing to set, first check the diagnostic trouble code if there are any trouble codes stored in memory. If there are trouble codes, make a note of them, then clear them and proceed to ”3 Problem Symptom Confirmation”. 3. PROBLEM SYMPTOM CONFIRMATION, 4 SYMPTOM SIMULATION Confirm the problem symptoms. If the problem does not reappear, be sure to simulate the problem by mainly checking the circuits indicated by the diagnostic trouble code in step 2, using ”Problem Simulation Method”. 5. DIAGNOSTIC TROUBLE CODE CHECK Check the diagnostic trouble codes. Determine if the problem is in the sensors or the wire harness. If a malfunction code is present, proceed to ”6 Diagnostic Trouble Code Chart”. If the normal code is output, proceed to ”7 Matrix Chart Problem Symptoms”. Be sure to proceed to ”6 Diagnostic Trouble Code Chart” after 2 and 3 . If troubleshooting is attempted after only the first malfunction code in the memory is output, errors could be made in the diagnosis. 6. DIAGNOSTIC TROUBLE CODE CHART If a trouble code is confirmed in the diagnostic trouble code check, proceed to the check procedure indi– cated by the matrix chart for each diagnostic code. 7. MATRIX CHART OF PROBLEM SYMPTOMS If the normal code is confirmed in the diagnostic trouble code check, perform inspection in accordance with the inspection order in the matrix chart of problem symptoms. 8. CIRCUIT INSPECTION Proceed with diagnosis of each circuit in accordance with the inspection order in 6 and 7 . Determine whether the cause of the problem is in the sensor, actuators, wire harness and connectors, or the ECU. 9. INPUT SIGNAL CHECK Check whether signals from the stop light switch and park/neutral position switch, etc. are input nor– mally to the ECU. This check is indicated in the flow chart for each circuit. 10. CONFIRMATION TEST After completing repairs, confirm not only that the malfunction is eliminated, but also perform a drive test, etc. to make sure the entire cruise control system is operating correctly. BE–166 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Items inside are titles of pages in this manual, with the page number indicated in the bottom portion. Seethe indicated pages for detailed–explanations: Vehicle Brought to Workshop Customer Problem Analysis P. BE–167 Check and Clear Diagnostic Trouble Codes (Precheck) P. BE–170 Symptom does not occur Symptom Simulation . Problem Symptom Confirmation P. IN–24 Symptom occur Diagnostic Trouble Code Check Normal code P. BE–168 ~ BE–171 Malfunction Code Diagnostic Trouble Code Chart Matrix Chart of Problems Symptoms P. BE–178 P. BE–171 Circuit Inspection Input Signal Check Parts Inspection P. BE–190 ~ BE–231 Identification of Problem Repair Confirmation Test Step 2 , 5 , 8 , 10 END : Diagnostic steps permitting the use of the TOYOTA hand–held tester or TOYOTA break–out–box. BE–167 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM CUSTOMER PROBLEM ANALYSIS CHECK SHEET BE–168 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DIAGNOSIS SYSTEM INDICATOR CHECK 1. Turn the ignition switch to ON. 2. Check that the CRUISE MAIN indicator light comes on when the cruise control main switch is turned on, and that the indicator light goes oft when the main switch is turned OFF. HINT: If the indicator check result is not normal, pro– ceed to troubleshooting (See page BE–65) for the com– bination meter section. DIAGNOSTIC TROUBLE CODE CHECK HINT: If a malfunction occurs in the speed sensors or actuator, etc. during cruise control driving, the ECU actuates AUTO CANCEL of the cruise control and blinks the CRUISE MAIN indicator light 5 times to inform the driver of a malfunction. At the same time, the malfunction is stored in memory as a diagnostic trouble code. Output of Diagnostic Trouble Code Using diagnosis check wire: 1. Turn the ignition switch ON. 2. Using SST, connect terminals Tc and E1 of DLC2. 3. Read the diagnostic trouble code on the CRUISE MAIN in– dicator light. HINT: If the diagnostic trouble code is not output, in– spect the Tc circuit (See page BE–230). As an example, the blinking patterns for codes; normal, 11 and 21 are shown in the illustration. 4. Check for the problem using the diagnostic trouble code table on the next page. 5. After completing the check, disconnect terminals Tc and E1, and turn off the display. BE–169 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM ECU DATA MONITOR USING TOYOTA HAND–HELD TESTER 1. Hook up the TOYOTA hand–held tester to the DLC2. 2. Monitor the ECU data by following the prompts on the tester screen. HINT: TOYOTA hand–held tester had a ”Snapshot” function which records the monitored data. Please refer to the TOYOTA hand–held tester operator’s manual for further details. ECU TERMINAL VALUES MEASUREMENT USING TOYOTA BREAK–OUT–BOX AND TOYOTA HAND–HELD TESTER 1. Hook up the TOYOTA hand–held tester and TOYOTA break–out– box to the vehicle. 2. Read the ECU input/output values by following the prompts on the tester screen. HINT: TOYOTA hand–held tester has a ”Snapshot” func– tion. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the TOYOTA hand–held tester/TOYOTA break out–box operators manual for further details. BE–170 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE Code No. CRUISE MAIN Indicator Light Blinking Pattern Diagnosis Normal • • Duty ratio of 100% output to motor acceleration side. Overcurrent (short) in motor circuit. • • Overcurrent (short) in magnet clutch circuit. Open in magnet clutch circuit. • • • Open in actuator motor circuit. Position sensor detects abnormal voltage. Position sensor signal value does not change when the motor operates. • Speed signal is not input to the ECU. • Actual vehicle speed has dropped by 16 km/h (10 mph) or more below the set speed during cruising. • Short in control switch circuit. • Voltage abnormality in control switch circuit. When 41 code is indicated, replace the cruise control ECU. HINT: When 2 or more codes are indicated, the lowest numbered code will be displayed first. (*) When the vehicle speed is reduced on uphill roads, the speed can be set again and driving continued. (This is not a malfunction.) Diagnostic Trouble Code Clearance 1. After completing repairs the diagnostic trouble code re– tained in memory can be cleared by removing the STOP fuse for 10 seconds or more, with the ignition switch off. 2. Check that the normal code is displayed after connecting the fuse. BE–171 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check, check the circuit listed for that code in the table below and proceed to the page given. Circuit Inspection Code No. 32,34 Page • Actuator Motor Circuit BE–190 • Actuator Magnet Clutch Circuit BE–192 • • Actuator Motor Circuit Actuator Position Sensor Circuit BE–190 BE–196 • Speed Sensor Circuit BE–198 • • • Actuator Control Cable Speed Sensor Circuit Actuator Motor Circuit BE–232 BE–198 BE–190 • Control switch circuit. (cruise control switch BE–202 HINT: 1. If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow chart for each circuit, proceed to the circuit with the next highest number in the table to continue the check. 2. If the trouble still reappears even though there are no abnormalities in any of the other circuits, then check or replace the Cruise control ECU as the last step. BE–172 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INPUT SIGNAL CHECK Output of Code 1. (a) For check No. 1 – No.2 Turn the ignition switch on. (b) For check No.3 – No.7 (1) Turn the ignition switch on. (2) Shift to D position. (e) For check No.8 – No.9 (1) Jack up the vehicle. (2) Start the engine. (3) shift to D position. 2. Press the control switch to SET/COAST or RES/ACC posi– tion and hold it down 1 or up 1. 3. Push the main switch on 2. 4. Check that the CRUISE MAIN indicator light blinks twice or 3 times repeatedly after 3 seconds. 5. Turn the SET/COAST or RES/ACC switch oft. 6. Operate each switch as listed in the table below. 7. Read the blinking pattern of the CRUISE MAIN indicator light. 8. After performing the check, turn the main switch oft. HINT: When two or more signals are input to the ECU, only the lowest–numbered code is displayed. No. Operation Method CRUISE MAIN Indicator Light Blinking Pattern Diagnosis Turn SET/COAST switch ON. SET/COAST switch circuit is norm al. Turn RES/ACC switch ON. RES/ACC switch circuit is normal. Turn CANCEL switch ON. CANCEL switch circuit is normal. Turn stop light switch ON. (Depress brake pedal) Stop light switch circuit is normal. Turn parking brake switch ON. Par–king brake switch circuit is normal. Turn park/neutral position switch ON. (Shift to N or P position.) Park/Neutral Position switch circuit is normal. Turn clutch start switch ON. (Depress clutch pedal.) Clutch switch circuit is normal. Drive at 40 km/h (25 mph) or higher. Speed sensor is normal. Drive at 40 km/h (25 mph) or below. BE–173 BODY ELECTRICAL SYSTEM – MEMO – – CRUISE CONTROL SYSTEM BE–174 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM WIRING DIAGRAM BE–175 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM TERMINALS OF ECU CRUISE Control ECU Terminal Name No. Symbol Terminal Name No. Symbol Stop Light Switch Power Source Park/Neutral Position Switch or Clutch Switch Backup Power Source Parking Brake Switch Stop Light Switch Cruise Main Switch CRUISE MAIN Indicator Light CRUISE Control Switch Speed Sensor DLC2 ECM Electronically Controlled Transaxle No. 2 Solenoid Magnet Clutch (Actuator) Throttle Position Sensor Motor (Actuator) Position Sensor (Actuator) Motor (Actuator) Position Sensor (Actuator) Ground Position Sensor (Actuator) BE–176 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM STANDARD VALUE OF ECU TERMINAL Terminals Symbols Wiring Color Condition Always IG ON. Depress clutch pedal or P or N positions IG ON. Release clutch pedal and other positions. IG ON. Parking brake is operating. IG ON. Parking brake is not operating. IG ON. Main switch hold ON. (Indicator light ON) IG ON. Main switch OFF. (Indicator light OFF.) IG ON. Main switch ON. Main indicator light ON. IG ON. Main switch OFF. Main indicator light OFF. Ignition switch ON. Ex. during cruise control driving. During cruise control driving and O/D switch OFF (3rd driving) During cruise control driving. Ex. during cruise control driving. During cruise control driving and SET/COAST Switch hold ON. Ex. during cruise control driving. During cruise control driving. Ex. during cruise control driving. Always Ignition switch ON. Always Standard Value BE–177 BODY ELECTRICAL SYSTEM Terminals Symbols – CRUISE CONTROL SYSTEM Wiring color Condition Depress brake pedal. Release brake pedal. IG ON. Main switch ON. Switch neutral position. IG ON. Main switch ON. CANCEL Switch hold ON. IG ON. Main switch ON. SET/COAST Switch hold ON. IG ON. Main switch ON. RESUME/ACCEL Switch hold ON. English start. Stop a vehicle. During driving. During cruise control. driving. O/D Switch ON. During cruise control driving. O/D Switch OFF (3rd driving) IG ON. Throttle valve fully opened. IG ON. Throttle valve fully closed. Ignition switch ON. During cruise control driving. IG ON. Control plate fully opened. IG ON. Control plate fully closed. Always Standard Value BE–178 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM MATRIX CHART OF PROBLEM SYMPTOMS SET not occurring or CANCEL occurring. (Diag. trouble code is Normal) SET not occurring or CANCEL occurring. Diag trouble code does not output. Actual vehicle speed deviates above or below the set speed. Gear shifting is frequent between 3rd and OD when driving on uphill road. (Hunting) Cruise control not cancelled, even when parking brake pedal is depressed. Cruise control not cancelled, even when parking brake is operating. Cruise control not cancelled, even when clutch pedal is depressed. Cruise control not cancelled, even when transaxle is shifted to ”N” position. Control switch does not operate. (SET/COAST, ACC/RES, CANCEL not possible) SET possible at 44 km/h (25 mph) or less, or CANCEL does not operate at 40 km/h (25 mph) or less. Poor response in ACCEL and RESUME modes. O/D does not Resume, even though the road is not uphill. Diagnostic trouble code memory is erased. Diagnostic trouble code is not output, or is output when it should not be. Cruise MAIN indicator light remains ON or fall to light up. BE–216 BE–212 Combination meter troubleshooting on page BE–65. Parking Brake Switch Circuit Electrically Controlled Transaxle Communication Circuit BE–206 BE–210 Idle Switch Circuit (main throttle position sensor) Control Switch Circuit (Cruise Control Switch) Speed Sensor Circuit Symptom Actuator Suspect Area Stop Light Switch Circuit BE–202 BE–198 See Page BE–190 BE–192 BE–196 If a normal code is displayed during the diagnostic trouble code check but the trouble still occurs (reappears), perform troubleshooting for each problem symptom, checking the circuits for each symptom in the order given in the table below. Proceed to the page located for each circuit. BE–179 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM BE–232 IN–36 Actuator Control Cable Cruise Control ECU BE–230 TC Terminal Circuit BE–228 Main Switch Circuit (Cruise Control Switch) BE–226 BE–222 ECU Power Source Circuit Back–up Power Source Circuit BE–220 Symptom Clutch switch Circuit Suspect Area BE–218 See Page Park/Neutral Position Switch Circuit HINT: 1. If the instruction ”Proceed to next circuit inspection shown on matrix chart” is given in the flow chart for each circuit, proceed to the circuit with the next highest number in the table to continue the check. 2. If the trouble still reappears even though there are no abnormalities in any of the other circuits, then check or replace the cruise control ECU as the last step. SET not occurring or CANCEL occurring. (Diag. trouble code is Normal) SET not occurring or CANCEL occurring. Diag trouble code does not output. Actual vehicle speed deviates above or below the set speed. Gear shifting is frequent between 3rd and OD when driving on uphill road. (Hunting) Cruise control not cancelled, even when parking brake pedal is depressed. Cruise control not cancelled, even when parking brake is operating. Cruise control not cancelled, even when clutch pedal is depressed. Cruise control not cancelled, even when transmission is shifted to ”N” position. Control switch does not operate. (SET/COAST, ACC/RES, CANCEL not possible) SET possible at 40 km/h (25 mph) or less, or CANCEL does not operate at 40 km/h (25 mph) or less. Poor response in ACCEL and RESUME modes. O/D does not Resume, even though the road is not uphill. Diagnostic trouble code memory is erased. Diagnostic trouble code is not output, or is output when is should not be. Cruise MAIN indicator light remains ON or fall to light up. Combination meter troubleshooting on page BE–65 BE–180 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM LOCATION OF CONNECTORS Location of Connectors in Engine Compartment BE–181 BODY ELECTRICAL SYSTEM 1 MZ–FE – CRUISE CONTROL SYSTEM BE–182 BODY ELECTRICAL SYSTEM 5S–FE – CRUISE CONTROL SYSTEM BE–183 BODY ELECTRICAL SYSTEM 5S–FE – CRUISE CONTROL SYSTEM BE–184 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Location of Connectors in Instrument Panel BE–185 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM BE–186 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Location of Connectors in Instrument Panel BE–187 BODY ELECTRICAL SYSTEM J/B No. 1 – CRUISE CONTROL SYSTEM_ BE–188 BODY ELECTRICAL SYSTEM JI6 No.3 – CRUISE CONTROL SYSTEM BE–189 BODY ELECTRICAL SYSTEM Location of Connectors in Body – CRUISE CONTROL SYSTEM BE–190 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM CIRCUIT INSPECTION DTC 11 13 Actuator Motor Circuit CIRCUIT DESCRIPTION The actuator motor is operated by signals from the EC U. Acceleration and deceleration signals are transmitted by changes in the Duty Ratio (See note below). Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, if A is the period of continuity in one cycle, and B is the period of non–continuity, then Duty Ratio = AA B x 100 (
o) Code No. • • • Diagnosis Duty ratio of 100% output to motor acceleration side. Overcurrent (short) in motor circuit. Open in actuator motor circuit. Trouble area • • • Cruise control actuator motor. Harness or connector between actuator motor and ECU. ECU DIAGNOSTIC CHART Check actuator motor. Check harness and connector between cruise control ECU and actuator motor. Proceed to next circuit inspection shown on matrix chart (See page BE–178). However, when diag. trouble code 11, 13 is displayed, check and replace Cruise Control ECU. WIRING DIAGRAM Replace actuator assembly. Repair or replace harness or connector. BE–191 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check actuator motor. 1. Remove cruise control actuator. 2. Disconnect actuator connector. 1. Connect positive + lead to terminal 5 and negative – lead to terminal 4 of actuator connector. (Magnet clutch ON) 2. When battery positive voltage is applied to each terminals of actuator connector, check that the control plate moves smoothly with– out hesitating. Connect Terminal Moving direction Acceleration side Deceleration side 3. With the motor rotating as in 2, check that the motor is stopped by limit switches when the control plate moves to fully opened or fully closed position. Replace actuator assembly. Check harness and connector between cruise control ECU and actuator motor. (See page IN–31) Repair or replace harness or connector. Proceed to next circuit inspection shown on matrix chart (See page BE–178). However, when diag. trouble code 11, 13 is displayed, check and replace Cruise Control ECU. BE–192 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DTC 12 Actuator Magnet Clutch Circuit CIRCUIT DESCRIPTION This circuit turns on the magnet clutch inside the actuator during cruise control operation according to the signal from the ECU. If a malfunction occurs in the actuator or speed sensor, etc. during cruise control, the rotor shaft between the motor and control plate is released. When the brake pedal is depressed, the stoplight switch turns on, supplying electrical power to the stoplight. Power supply to the magnet clutch is mechanically cut and the magnet clutch is turned OFF. When driving downhill, if the vehicle speed exceeds the set speed by 15 km/h (9 mph), the ECU turns the magnet clutch OFF. If the vehicle speed later drops to within 10 km/h (6 mph) above the set speed, then cruise control at the set speed is resumed. Diagnosis Code No. • • Overcurrent (short) in magnet clutch circuit. Open in magnet clutch circuit. Trouble area • • • Cruise control magnet clutch. Harness or connector between ECU and magnet clutch, magnet clutch and body ground. ECU DIAGNOSTIC CHART Check actuator magnet clutch. Replace actuator assembly. Check stop light switch. Replace stop light switch. Check harness and connector between cruise control ECU and stop light switch, stop light switch and magnet clutch, magnet clutch and body ground. Repair or replace harness or connector. Proceed to next circuit inspection shown on matrix chart (See page BE–178). However, when diag. trouble code 12 is displayed, check harness and connector for loose connection. If connection is normal, check and replace Cruise Control ECU. BE–193 BODY ELECTRICAL SYSTEM WIRING DIAGRAM – CRUISE CONTROL SYSTEM BE–194 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check actuator magnet clutch. 1. Remove cruise control actuator. 2. Disconnect actuator connector. Move the control plate by hand. Control plate moves. (Magnet clutch off) 1. Connect positive + lead to terminal 5 and negative – lead to terminal 4 of actuator connector. 2. Move the control plate by hand. Control plate doesn’t move. (Magnet clutch on) Replace actuator assembly. Check stop light switch. Disconnect stop light switch connector. Check continuity between terminals. Continuity Terminal Switch position Switch pin free (Brake pedal depressed) Switch pin pushed in (Brake pedal released) Replace stop light switch. Check harness and connectors between cruise control ECU and stop light switch, stop light switch and magnet clutch, magnet clutch and body ground. (See page IN–31) Repair or replace harness or connector. Proceed to next circuit inspection shown on matrix chart (See page BE–178). However, when diag trouble code 12 is displayed, check harness and connector for loose connection. If connection is normal, check and replace Cruise Control ECU. BE–195 BODY ELECTRICAL SYSTEM – MEMO – – CRUISE CONTROL SYSTEM BE–196 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DTC 13 Actuator Position Sensor Circuit CIRCUIT DESCRIPTION This circuit detects the rotation position of the actuator control plate and sends signal to the ECU. Trouble area Diagnosis Code No. • • Position sensor detects abnormal voltage. Position sensor signal value does not change when the motor operates. • • • Cruise control actuator Position sensor. Harness or connector between actuator position sensor and body ground. ECU DIAGNOSTIC CHART Check voltage between terminals VR2 and VR3 of cruise control ECU connector. Check actuator position sensor. Replace actuator assembly. Check harness and connector between cruise control ECU and actuator position sensor. Replace or replace harness or connector. Check harness and connector for loose connection. If connection is normal, check and replace Cruise Control ECU. WIRING DIAGRAM BE39 Proceed to next circuit inspection shown on matrix chart (See page BE–178). BE–197 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check voltage between terminals VR2 and VR3 of cruise control ECU connector. Remove cruise control ECU with connectors still connected. 1 Turn ignition switch on. 2. Measure voltage between terminals VR2 and VR3 of cruise control ECU connector while turning control plate slowly by hand from the deceleration side to the acceleration side. Voltage: Fully closed: 1.1–1.4 V Fully opened: 3.8–4.5 V In addition, as the control plate is turned, the voltage should increase gradually without interruption. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check actuator position sensor. 1 Remove cruise control actuator. 2. Disconnect the actuator connector. Measure resistance between actuator terminals 1 and 3 of actuator connector. Resistance: 1.8–2.2 kΩ Measure resistance between terminals 2 and 3 of actuator connector, while turning the control plate slowly by hand from the deceleration side to the acceleration side. Resistance: Fully closed: 500–550Ω Fully opened: 1.5–2.0 kΩ In addition, as the control plate turns, the resistance should increase gradually without interruption. Replace actuator assembly. Check harness and connector between cruise control ECU and actuator position sensor. (See page IN–31) Repair or replace harness or connector. Check harness and connector for loose connection. If connection is normal check and replace cruise control ECU. BE–198 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DTC 21 23 Speed Sensor Circuit CIRCUIT DESCRIPTION The speed sensor signal is sent to cruise control ECU as vehicle speed signal. Code No. Trouble area Diagnosis Speed signal is not input to the ECU • • • • Actual vehicle speed has dropped by 16 km/h (10 mph) or more below the set speed during cruising. HINT: When speed sensor circuit is opened intermittently (Below 0.2 sec), code 23 is output. • • • • • Speed sensor Combination meter Harness or connector between speed sensor and combination meter, combination meter and ECU. ECU Actuator Actuator control cable Speed sensor Harness or connector in OD and SPD circuit (Open or short intermittently) ECU DIAGNOSTIC CHART Input signal check. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check speedometer circuit.(See combination meter troubleshooting on page BE–63). Repair or replace speed sensor, harness, connector or combination meter assembly. Check harness and connector for loose connection. If connection is normal, check and replace cruise control ECU. BE–199 BODY ELECTRICAL SYSTEM WIRING DIAGRAM – CRUISE CONTROL SYSTEM BE–200 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Input signal check. 1 See input signal check on page BE–172. 2. Check indicator light operation when driving with vehicle speed above 40 km/h (25 mph), and with vehicle speed below 40 km/h (25 mph). Vehicle speed above 40 km/h (25 mph) : Indicator light blinks Vehicle speed below 40 km/h (25 mph) : Indicator light stays on Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check speedometer circuit. (See combination meter troubleshooting on page BE–63). Repair or replace speed sensor, harness, connector or combination meter assembly. Check harness and connector for loose connection. If connection is normal, check and replace cruise control ECU. BE–201 BODY ELECTRICAL SYSTEM – MEMO – – CRUISE CONTROL SYSTEM BE–202 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM DTC 32 34 Control Switch Circuit (Cruise Control Switch) CIRCUIT DESCRIPTION This circuit carries the SET/COAST, RESUME/ACCEL and CANCEL signals (each voltage) to the ECU. Code No. Diagnosis Short in, control switch circuit. Voltage abnormality in control switch circuit. Trouble area • • • Cruise control switch. Harness or connector between control switch and ECU. ECU DIAGNOSTIC CHART Input signal check. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check voltage between terminal CCS of cruise control ECU connector and body ground. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check control switch. Replace cruise control switch. Check harness and connector between cruise control ECU and control switch. Repair or replace harness or connector. Check and replace cruise control ECU. WIRING DIAGRAM BE–203 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Input signal check. Input signal SET/COAST SWITCH RESUME ACCEL SWITCH CANCEL SWITCH Indicator light blinking pattern 1 See input signal check on page BE–172. 2. Check the indicator light operation when each of the SET/COAST, RESUME/ACCEL and CANCEL is turned ON. SET/COAST, RESUME/ACCEL switch The signals shown in the table on the left should be output when each switch is ON. The signal should disappear when the switch is turned OFF. CANCEL switch The indicator light goes off when the cancel switch is turned ON. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check voltage between terminal CCS of cruise control ECU connector and body ground. Remove cruise control ECU with connectors still connected. 1 Turn ignition switch ON. 2. Measure voltage between terminal CCS of cruise control ECU connector and body ground, when each of the SET/COAST, RESUME/ACCEL and CANCEL is turned ON. Switch position Neutral RES/ACC Voltage 10–14 V 0.7–2.5 V SET/COAST 2.3–4.6 V CANCEL 4.1–7.2 V Proceed to next circuit inspection shown on matrix chart (See page BE–178). Go to step BE–204 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Check control switch. 1 Remove steering wheel center pad. 2. Disconnect control switch connector. Measure resistance between terminals 3 and 4 of control switch connector when control switch is operated. Switch position Neutral RES/ACC Resistance 1 Mn or higher SET/COAST 60–80
190–2100 CANCEL 410–4300 When diagnostic trouble code 34 is displayed, carefully check that resistance is always 1 Mil or higher in neutral position, particularly when switching between REC/ACC and SET/COAST. Replace cruise control switch. Check harness and connector between cruise control ECU and control switch. (See page IN–31) Repair or replace harness or connector. Check and replace cruise control ECU. BE–205 BODY ELECTRICAL SYSTEM – MEMO – – CRUISE CONTROL SYSTEM BE–206 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Stop Light Switch Circuit CIRCUIT DESCRIPTION When the brake is on, battery voltage normally applies through the stop fuse and stop switch to terminal STP– of the ECU, and the ECU turns the cruise control off. A fail–safe function is provided so that the cancel functions normally, even if there is a malfunction in the stop light signal circuit. 1 If the harness connected to terminal STP– has an open, terminal STP– will have battery positive voltage and the cruise control will be turned off, also SET not occurring. 2 If the stop fuse is open, terminal STP+ becomes approx. 0 V when the brake is turned on, so the ECU performs cancel function normally. Also, shown the brake is on, the magnet clutch circuit is cut mechanically by the stop light switch, turn– ing the cruise control off. (See page BE–190 for operation of the magnet clutch.) DIAGNOSTIC CHART Check operation of stop light. Check stop light circuit (See page BE–50). Input signal check. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check voltage between terminal STP+ STP– of cruise control ECU connector and body ground. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check for open in harness and connectors between terminal STP+ of cruise control ECU and stop light switch, terminal STP– of cruise control ECU and stop Iight switch. Check and replace cruise control ECU. Repair or replace harness or connector. BE–207 BODY ELECTRICAL SYSTEM WIRING DIAGRAM – CRUISE CONTROL SYSTEM BE–208 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check operation of stop light. Check that stop light comes on when brake pedal is depressed, and turns off when brake pedal is released. Check stop light circuit (See page BE–50). Input signal check. 1. See input signal check on page BE–172. 2. Check the indicator light when the brake pedal is depressed. The indicator light goes off when the brake pedal is depressed. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check voltage between terminal STP+, STP– of cruise control ECU connector and body ground. Remove cruise control ECU with connectors still connected. 1. Turn ignition switch ON. 2. Measure voltage between terminal STP+, STP– of cruise control ECU connector and body ground, when the brake pedal is depressed and released. STP+ STP– Depressed 10– 14V 10– 14V Released 10–14V Below 1 V Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check for open in harness and connectors between terminal STP+ of cruise control ECU and stop light switch, terminal STP– of cruise control ECU and stop light switch. (See page IN–31) Repair or replace harness or connector. Check and replace cruise control ECU. BE–209 BODY ELECTRICAL SYSTEM – MEMO – – CRUISE CONTROL SYSTEM BE–210 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Idle Switch Circuit CIRCUIT DESCRIPTION When the idle switch is turned ON, a signal is sent to the ECU. The ECU uses this signal to enable accurate cruise control at the set speed quickly. If the idle switch is malfunctioning, problem symptoms also occur in the engine, so also inspect the engine. DIAGNOSTIC CHART Check voltage between terminal IDL of cruise control ECU connector and body ground. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check throttle position sensor. Replace throttle position sensor. Check harness and connector between cruise control ECU and throttle position sensor, throttle position sensor and body ground. Repair or replace harness or connector. Check and replace cruise control ECU. WIRING DIAGRAM BE–211 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check voltage between terminal IDL of cruise control ECU connector and body ground. 1. Remove cruise control ECU with connectors still connected. 2. Disconnect ECM and ABS & TRAC ECU con– nector. 1. Turn ignition switch ON. 2. Measure voltage between terminal IDL of cruise control ECU connector and body ground, when the throttle valve is fully closed and fully opened. Throttle valve position Voltage Fully opened 10– 14V Fully closed Below 1 V Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check throttle position sensor. Disconnect throttle position sensor connector. Measure resistance between terminals 1 and 2 of throttle position sensor connector, when the throttle valve is fully closed and fully opened. Throttle valve position Fully opened Fully closed Resistance 1 Mil or higher Below 2
Replace throttle position sensor. Check harness and connector between cruise control ECU and throttle position sensor, throttle position sensor and body ground. (See page IN–31) Repair or replace harness or connector. Check and replace cruise control ECU. BE–212 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM_ Electronically Controlled Transaxle Communication Circuit CIRCUIT DESCRIPTION CIRCUIT DESCRIPTION When driving uphill under cruise control, in order to reduce shifting due to ON–OFF overdrive opera– tion and to provide smooth driving, when down shifting in the electronically controlled transaxle oc– curs, a signal to prevent upshift until the end of the uphill slope is sent from the cruise control ECU to the ECM. Terminal ECT of the cruise control ECU detects the shift change signal (out–put to electronically con– trolled transaxle No.2 solenoid) from the ECM. If vehicle speed down and terminal ECT of the control ECU receivers down shifting signal, it sends a signal from terminal OD to ECM to cut overdrive until the end of the uphill slope, and the gearshifts are reduced. DIAGNOSTIC CHART Check operation of overdrive. Check and repair electronically controlled transaxle (See page AX’ Section). Check voltage between terminal OD of harness side connector of cruise control ECU and bod round. Check voltage between terminal ECT of cruise control ECU connector and body ground (ON test drive). Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check harness and connector between terminal ECT of cruise control ECU and electronically controlled transaxle No.2 solenoid. (Seepage IN–31 ) Repair or replace harness or connector. Check and repair cruise control ECU. Check harness and connector between terminal OD of cruise control ECU and terminal OD 1 of ECM. Check and replace ECM. Repair or replace harness or connector. BE–213 BODY ELECTRICAL SYSTEM WIRING DIAGRAM – CRUISE CONTROL SYSTEM BE–214 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check operation of overdrive. Test drive after engine warm up. Check that overdrive ON H OFF occurs with operation of OD switch ON–OFF. Check and Repair Electronically Controlled Transaxle (See page AX Section). Check voltage between terminal OD of harness side connector of cruise control ECU and body ground. Remove cruise control ECU with connectors still connected. 1. Disconnect cruise control ECU connector. 2. Turn ignition switch ON. 3. Measure voltage between terminal OD of harness side connector of cruise control ECU and body ground. Voltage: 10 – 14 V Go to step Go to step BE–215 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Check voltage between terminal ECT of cruise control ECU connector and body ground (On test drive). 1. Connect cruise control electronically controlled transaxle connector. 2. Test drive after engine warm up. Check voltage between terminal ECT of cruise control ECU connector and body ground when OD switch is on and off. Gear Position Voltage O/D Below 1 V 3rd 10 – 14 V Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check harness and connector between terminal ECT of cruise control ECU and solenoid. (See page IN–31) Repair or replace harness or connector. Check and repair cruise control ECU. Check harness and connector between terminal OD of cruise control ECU and terminal OD1 of ECM. (See page IN–31) Repair or replace harness or connector. Check and replace ECU. BE–216 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Parking Brake Switch Circuit CIRCUIT DESCRIPTION When the parking brake is operating , the parking brake switch sends a signal to the ECU. When this signal is input to the ECU during cruise control driving, the ECU cancels cruise control. DIAGNOSTIC DIAGNOSTIC CHART CHART Check operation of brake warning light. Check brake warning light circuit (See page BE–61). Input signal check. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check voltage between terminal PKB of cruise control ECU connector and body ground. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check for open in harness and connector between cruise control ECU and brake warning light. Repair or replace harness or connector. Check and replace cruise control ECU. WIRING DIAGRAM BE–217 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check operation of brake warning light. Check that the brake warning light in the instrument panel comes on when the parking brake is operating with the engine running, and the light goes off when the parking brake is not operating. Check brake warning light circuit (See page BE–64). Input signal check. 1. See input signal check on page BE–172. 2. Check the indicator light when the parking brake is operating. The indicator light goes off when the parking brake is operating. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check voltage between terminal PKB of cruise control ECU connector and body ground. Remove cruise control ECU with connectors still connected. 1. Turn ignition switch ON. 2. Measure voltage between terminal PKB of cruise control ECU connector and body ground, when the parking brake lever is operating. Switch Position Voltage ON (lever pulled) Below 1 V OFF (lever released) 10 – 14 V Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check for open in harness and connector between cruise control ECU and brake warning light. (See page IN–31) Repair or replace harness or connector. Check and replace cruise control ECU. BE–218 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Park Neutral Position Switch Circuit CIRCUIT CIRCUIT DESCRIPTION DESCRIPTION When the shift position is put in P or N, a signal is sent from the park/neutral position switch to the ECU. When this signal is input during cruise control driving, the ECU cancels the cruise control. DIAGNOSTIC CHART Check operation of starter. Proceed to engine trouble– shooting.(See page EG Section) Input signal check. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check voltage between terminal N & C of cruise control ECU connector and body round. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check for open in harness and connector between cruise control ECU and ST fuse. (See page IN–31) Repair or replace harness or connector. Check and replace cruise control ECU. WIRING DIAGRAM BE–219 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check operation of starter. Check that the starter operates normally and that the engine starts. Proceed to engine troubleshooting (See page EG Section). Input signal check. 1. See input signal check on page BE–172. 2. Check the indicator light when shifting into P position or N position. The indicator light goes off when shifting into P position or N position. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check voltage between terminal N & C of cruise control ECU connector and body ground. Remove cruise control ECU with connectors still connected. 1. Turn ignition switch ON. 2. Measure voltage between terminal N & C of cruise control ECU connector and body ground, when shifting into P, N position and other positions. Switch Position Voltage P or N position Below 1 V Other positions 10– 14V Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check for open in harness and connector between cruise control ECU and ST fuse. (See page IN–31) Repair or replace harness or connector. Check and replace cruise control ECU. BE–220 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Clutch Switch Circuit (5S–FE MT Vehicles) CIRCUIT DESCRIPTION When the clutch pedal is depressed, the clutch switch sends a signal to the ECU, when this signal is input to the ECU during cruise control driving, the ECU cancels cruise control. DIAGNOSTIC CHART Check operation of starter. Proceed to engine trouble– shooting.(See page EGI Section) Input signal check. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check voltage between terminal N & C of cruise control ECU connector ECU connector and body ground. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check for open in harness and connector between terminal N & C of cruise control ECU and clutch switch. (See page IN–31) Repair or replace harness or connector. Check and replace cruise control ECU. WIRING DIAGRAM BE–221 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check operation of starter. Check that the starter operates normally and that the engine starts. Proceed to engine troubleshooting (See page EG Section). Input signal check. 1. See input signal check on page BE–172. 2. Check the indicator light when shifting into P range or N position. The indicator light goes off when the clutch pedal is depressed. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check voltage between terminal N & C of cruise control ECU connector and body ground. Remove cruise control ECU with connectors still connected. 1. Turn ignition switch ON. 2. Measure voltage between terminal N & C of cruise control ECU connector and body ground, when the clutch pedal is depressed. Switch Position Voltage ON (pedal depressed) Below 1 V OFF 10 – 14 V Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check for open in harness and connector between cruise control ECU and ST fuse. Repair or replace harness or connector. Check and replace cruise control ECU. BE–222 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM ECU Power Source Circuit CIRCUIT DESCRIPTION The ECU power source supplies power to the actuator. Terminal GND and the cruise control ECU case are grounded. DIAGNOSTIC CHART Check ECU–IG fuse. Check for short in all the harness and components connected to the ECU–IG fuse (See attached wire diagram). Check voltage between terminals B and GND of cruise control ECU connector. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check continuity between terminal GND of cruise control ECU connector and body ground. Repair or replace harness or connector. Check and repair harness and connector between battery and cruise control ECU. WIRING DIAGRAM BE–223 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check ECU–IG fuse. Remove ECU–IG fuse from J/B No. 1. Check continuity of ECU–IG fuse. Continuity Check for short in all the harness and components connected to the ECU–IG fuse (See attached wiring diagram). Check voltage between terminals +B and GND of cruise control ECU connector. Remove cruise control ECU with connectors still connected. 1. Turn ignition switch ON. 2. Measure voltage between terminals +B and GND of cruise control ECU connector. Voltage: 10 – 14 V Proceed to next circuit inspection shown on matrix chart (See page BE–178). Go to step BE–224 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Check continuity between terminal GND of cruise control ECU connector and body ground. Measure resistance between terminal GND of cruise control ECU connector and body ground. Resistance: Below 1
Repair or replace harness or connector. Check and repair harness and connector between battery and cruise control ECU. BE–225 BODY ELECTRICAL SYSTEM – MEMO – – CRUISE CONTROL SYSTEM BE–226 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Back–up Power Source Circuit CIRCUIT DESCRIPTION The ECU back–up power source provides power even when the ignition switch is off and is used for diagnostic code memory, etc. DIAGNOSTIC CHART Check STOP fuse. Check voltage between terminals BATT of cruise control ECU connector and body ground. Check and repair harness and connector between battery and cruise control ECU. WIRING DIAGRAM Check for short in all the harness and components connected to the STOP fuse (See attached wiring diagram). Proceed to next circuit inspection shown on matrix chart (See page BE–178). BE–227 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check STOP fuse. Remove STOP fuse from JIB No. 1. Check continuity of STOP fuse. Continuity Check for short in all the harness and components connected to the STOP fuse (See attached wiring diagram). Check voltage between terminals BATT of cruise control ECU connector and body ground. Remove cruise control ECU with connectors still connected. Measure voltage between terminal BATT of cruise control ECU connector and body ground. Voltage: 10 – 14 V Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check and repair harness and connector between battery and cruise control ECU. BE–228 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Main Switch Circuit (Cruise Control Switch) CIRCUIT DESCRIPTION When the cruise control main switch is turned oft, the cruise control does not operate. DIAGNOSTIC CHART Check voltage between terminals CMS and GND of cruise control ECU connector. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check main switch. Replace cruise control switch. Check harness and connector between cruise control ECU and main switch, main switch and body ground. Repair or replace harness or connector. Check and replace cruise control ECU. WIRING DIAGRAM BE–229 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check voltage between terminals CMS and GND of cruise control ECU connector. 1. Remove cruise control ECU with connectors still connected. 2. Turn ignition switch ON. Measure voltage between terminals CMS and GND of cruise control ECU connector when main switch is hold on and off. Main switch Voltage OFF 10 – 14 V Hold on Below 1 V Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check main switch. 1. Remove steering wheel pad (See page RS–19). 2. Disconnect cruise control switch connector. Check continuity between terminals 3 and 5 of cruise control switch connector when main switch is hold on and off. continuity Terminals Main switch OFF Hold on Replace control switch. Check harness and connector between cruise control ECU and main switch, main switch and body ground. Repair or replace harness or connector. Check and replace cruise control ECU. BE–230 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM TC Circuit CIRCUIT DESCRIPTION This circuit sends a signal to the ECU that diagnostic code output is required. DIAGNOSTIC CHART Check voltage between terminals TC and El of DLC2. Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check harness and connector between cruise control ECU and DCL2, DLC2 and body ground. Repair or replace harness or connector. Check and replace cruise control ECU. WIRING DIAGRAM BE–231 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM INSPECTION PROCEDURE Check voltage between terminals TC and E1 of DLC2. 1. Turn ignition switch ON. 2. Measure voltage between terminals TC and El of DLC2. Voltage: 10 – 14 V Proceed to next circuit inspection shown on matrix chart (See page BE–178). Check harness and connector between cruise control ECU and DCL2, DLC2 and body ground. (See page IN–31) Repair or replace harness or connector. Check and replace cruise control ECU. BE–232 BODY ELECTRICAL SYSTEM – CRUISE CONTROL SYSTEM Actuator Control Cable Inspection 1. Check that the actuator, control cable and throttle link are properly installed and that the cable and link are connected correctly. 2. Check that the actuator and throttle link are operating smoothly. 3. Check that the cable is not loose or too tight. 1. If the control cable is very loose, the vehicle’s loss of speed going uphill will be large. 2. If the control cable is too tight, the idle rpm will become high. BO–1 BODY – BODY BO–2 BODY – GENERAL INFORMATION GENERAL INFORMATION HANDLING PRECAUTIONS Taping When it is possible that the body or parts may be scratched during the operation, apply protection tape before starting work. Example: 1. Before starting work, apply protection tape to body surfaces around parts to be removed and installed. 2. Before prying parts loose with a screwdriver or scraper etc., apply protection tape to the tip of the tool to avoid scratching parts or painted sur– faces of the body. Battery In order to prevent a short circuit while doing work on the electrical circuit such as disconnecting a connec– tor, first turn off the ignition switch and disconnect the negative (–) terminal cable from the battery ter– minal before starting work. HINT: When battery voltage is required for operation of a functioning part, connect the cable to the battery when needed, and promptly disconnect it when no longer necessary. CAUTION: • Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK‘ position and the negative (–) terminal cable is dis– connected from the battery. • To avoid erasing the memory of each memory system, never use a back–up power supply from outside the vehicle. Fitting Adjustments When removing and installing body panels which have a preload value, after their installation refer to the page containing the installation adjustment methods, and make adjustments according to the required spe– cifications. HINT: When making adjustments, do not completely loosen the bolts and nuts of the part being adjusted. Tighten them appropriately, and move the panels by hand to align them. BO–3 BODY – GENERAL INFORMATION ANTI–RUST TREATMENT Anti–rust treatment used on the vehicle body in– cludes body sealer, undercoat, rust inhibitor and paint. HINT: Refer to the Body Collision Damage ’Repair Manual for details of which parts have received anti – rust treatment. Body Sealer If the body sealer is damaged (peeling, cracks, etc.) during the operation, replace it with new body sealer. HINT: If body sealer gets on other parts, promptly wipe it off with a clean cloth dipped in a grease, wax and silicone remover. Undercoat If the undercoat is damaged during the operation, apply new undercoat. HINT: • Cover the surrounding area with masking paper to avoid applying undercoat where it is not needed. • Do not apply undercoat to high temperature parts such as the tailpipe, or to drive parts such as the drive shaft. Rust Inhibitor After removing and re–installing hinges and outer panel parts, apply rust inhibitor to the parts. HINT: If rust inhibitor gets spilled on other parts, promptly wipe it off with a clean cloth dipped in a grease, wax and silicon remover. Touch– Up Paint If a small scratch is made in the body surface, correct the scratch using touch–up paint the same color as the body color. BO–4 BODY – GENERAL INFORMATION CLIPS The removal and installation methods of typical clips used in body parts are shown in the table below. HINT: If the clip is damaged during the operation, always replace it with a new clip. Shape (Example) Removal/installation BO–5 BODY – GENERAL INFORMATION CLIPS (Cont’d) Shape (Example) Removal/installation BO–6 BODY – GENERAL INFORMATION SRS (Supplemental Restraint System) The 1994 CAMRY is equipped with an SRS, such as the driver airbag and front passenger airbag assembly. Failure to carry out service operations in the correct sequence could cause the SRS to deploy, possibly leading to a serious accident. When removing or installing, refer to the pre– cautionary notices in the RS section before perform– ing the operation. • Work must be started after 90 seconds from the time the ignition switch is set to the LOCK posi– tion and the negative (–) terminal cable is dis– connected from the battery. (The SRS is equipped with a back–up power source so that if work is started within 90 sec– onds of disconnecting the negative (–) terminal cable from the battery, the SRS may deploy.) • To avoid erasing the memory of each memory system, never use a back–up power supply from outside the vehicle. • Before repairs, remove the airbag sensors if shocks are likely to be applied to the sensors during repairs. • The front airbag sensor set bolt has been anti– rust treated. When the sensor is removed, always replace the set bolt with a new one. • If the front airbag sensors, center airbag sensor assembly, steering wheel pad or front passenger airbag assembly have been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. • Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. • Do not expose the front airbag sensors, center airbag sensor assembly, steering wheel pad or front passenger airbag assembly directly to hot air or flames. • The SRS wire harness is integrated with the cowl wire harness assembly. The wires for the SRS wire harness are encased in a yellow corrugated tube. All the connectors for the system are also a standard yellow color. If the SRS wire harness becomes disconnected or the connector bec– omes broken due to an accident, etc., repair or replace it. (See RS section) BO–7 BODY – GENERAL INFORMATION • The steering wheel must be fitted correctly to the steering column with the spiral cable at the neu– tral position; otherwise, cable disconnection and other troubles may result. Refer to RS section of this manual concerning correct steering wheel installation. • When removing or handling the steering wheel pad or front passenger airbag assembly, it should be placed with them top surface facing up. In this case, the twin–lock type connector lock lever should be in the locked state and care should be taken to place it so the connector will not be damaged. (Storing the pad with its metallic sur– face up, the front passenger airbag assembly with the airbag door facing down may lead to a serious accident if the airbag inflates for some reason.) • Grease should not be applied to the steering wheel pad or the front passenger airbag assem– bly, and they should not be cleaned with deter– gents of any kind. • Store the steering wheel pad or the front passen– ger airbag assembly where the ambient tempera– ture remains below 93
C (200
F), without high humidity and away from electrical noise. • Information labels are attached to the periphery of the SRS components. Follow the notices. • When the ignition switch is at ACC or ON and the SRS warning light remains on, the center airbag sensor assembly has detected a malfunction code. (See RS section) BO–8 BODY – PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) 09812–00020 Door Hinge Set Bolt Wrench 09804–24010 Luggage Compartment Door Torsion Bar Tool LUBRICANT Item Capacity Classification MP grease SSM (SPECIAL SERVICE MATERIALS) 08833–00070 Adhesive 1311, THREE BOND 1311 or equivalent Front Door Rear Door Sliding Roof 08850–00070 Windshield glass adhesive set No. 15 or equivalent Windshield Back Window Glass (0–15
C or 32–59
F) 08850–00080 Windshield glass adhesive set No.35 or equivalent Windshield Back Window Glass (15–35
C or 59–95
F) 08850–00090 Windshield glass adhesive set No.45 or equivalent Windshield Back Window Glass (35 – 45
C o r 95 –113
F) 08833–00030 Auto glass sealer or equivalent Windshield Moulding Back Window Moulding Windshield Back Window Glass 08850–00051 Adhesive (Super Special) or equivalent Side Protection Moulding BO–9 BODY Ambient temperature 0 – 160C (32 – 59
F) (59 – 95
F) 35 – 45
C (95 – 113
F) Part No. Part Name Windshield o8850–00070 glass adhesive set No. 15 Windshield 08850–00080 glass adhesive set No. 35 – PREPARATION 1. CHOOSE SUITABLE ADHESIVE SET Use an adhesive set suitable for the ambient temper– ature. Windshield 08850–00090 glass adhesive set No. 45 2. CHECK ADHESIVE USABLE TIME After mixing main and hardening agents, finish glass installation within the specified time as shown. Example: For glass installation in an ambient tempera– ture of 25
C (77
F), apply adhesive set No.35 within 45 minutes. 3. CHECK ADHESIVE HARDENING TIME After main and hardening agents are mixed, leak tests should be made only after the hardening time has elapsed. Example: The hardening time for adhesive set No.35 with and ambient temperature of 25
C (77
F) is 2 1/ 2 hours. NOTICE: Do not drive the vehicle until at least double the hardening time has elapsed. BO–10 BODY – FRONT BUMPER FRONT BUMPER COMPONENTS BO–11 BODY – FRONT BUMPER FRONT BUMPER REMOVAL 1. REMOVE RADIATOR GRILLE Remove 2 screws and the grille. 2. REMOVE CLEARANCE LIGHT (a) Remove the screw. (b) Pull the light forwards to remove it, then disconnect the connector. 3. REMOVE HEADLIGHT (a) Disconnect the connectors. (b) Remove 3 bolts, the nut and the headlight. 4. REMOVE FENDER LINER (a) Remove 7 screws. (b) Remove 3 bolts and the fender liner. 5. REMOVE SIDE MARKER LIGHT Remove the screw and the light, then disconnect the connector. 6. REMOVE TURN SIGNAL LIGHT Remove the screw and the light, then disconnect the connector. BO–12 BODY – FRONT BUMPER 7. REMOVE ENGINE UNDER COVER (a) Remove the clip (b) Remove 4 screws an the cover. 8. REMOVE INTAKE AIR RESONATOR Remove 2 bolts and the resonator. 9. REMOVE BUMPER COVER (a) Remove 4 clips and the upper retainer. (b) Remove 3 clips and the lower retainer. (c) Remove 2 clips. (d) Remove 3 bolts and 2 nuts. (e) Pull the cover forwards to remove it. 10. REMOVE FRONT BUMPER ENERGY ABSORBER (a) Remove 2 plates. (b) Remove 2 absorber from the bumper cover. (c) Remove 2 clips and 2 license brackets. (d) Remove 4 nuts. (e) Remove 2 fillers. BO–13 BODY – FRONT BUMPER 11. REMOVE FRONT BUMPER END RETAINER Remove 2 clips and the retainer. 12. REMOVE FRONT BUMPER SIDE SUPPORT (a) Using about 3.2 mm (0.128 in.) drill, drill out 2 rivet heads. (b) Remove the side support. 13. REMOVE UPPER REINFORCEMENT (a) Remove 4 nuts. (b) Remove 5 bolts and the upper reinforcement. (c) Remove 2 bolts and 2 deflectors. 14. REMOVE REINFORCEMENT EXTENSION Remove 4 bolts and the extension. 15. REMOVE FRONT BUMPER REINFORCEMENT Remove 4 bolts and the reinforcement. BO–14 BODY – FRONT BUMPER 16. REMOVE FRONT BUMPER ARM Remove 3 nuts and the bumper arm. FRONT BUMPER INSTALLATION INSTALL FRONT BUMPER PARTS BY FOLLOWING RE– MOVAL SEQUENCE IN REVERSE 1. INSTALL FOLLOWING PARTS: (a) Front bumper arm Torque: 8.8 N–m (90 kgf–cm, 78 in.–lbf) (b) Front bumper reinforcement Torque: 8.8 N–m (90 kgf–cm, 78in.–lbf) (c) Reinforcement extension Torque: 21 N–m (210 kgf–cm. 15 ft.–lbf) 2. INSTALL FRONT BUMPER SIDE SUPPORT (a) Place the side support in the bumper cover. (b) Using a riveter, install 2 rivets. BO–15 BODY – REAR BUMPER REAR BUMPER COMPONENTS BO–16 BODY – REAR BUMPER COMPONENTS (Cont’d) BO–17 BODY – REAR BUMPER REAR BUMPER REMOVAL 1. REMOVE REAR FLOOR FINISH PLATE Remove the finish plate by pulling. 2. REMOVE REAR LUGGAGE TRIM Using a clip remover, remove 4 clips and the trim. 3. REMOVE RIGHT SIDE LUGGAGE TRIM Using a clip remover, remove 6 clips and the trim. 4. REMOVE LEFT SIDE LUGGAGE TRIM Using a clip remover, remove 6 clips and the trim. 5. REMOVE REAR LICENSE PLATE LIGHT Remove 3 screws and the light, then disconnect the connector. 6. REMOVE REAR BUMPER COVER (a) Remove 9 bolts and 10 nuts. (b) Pull the cover rearwards to remove it. BO–18 BODY – REAR BUMPER 7. REMOVE REAR BUMPER ENERGY ABSORBER Remove the absorber from the bumper cover. 8. REMOVE REAR BUMPER SIDE SUPPORT (a) Using an approx. 3.2 mm (0.26 in.) drill, drill out 3 rivet heads. (b) Remove the side support. 9. REMOVE REAR BUMPER UPPER RETAINER (a) Remove 2 clips. (b) Remove 6 spacers. (c) Remove the retainer from the bumper cover. 10. REMOVE QUARTER AIR DUCT Remove 4 screws and the duct. 11. REMOVE REAR BUMPER REINFORCEMENT Remove 2 bolts and the reinforcement. BO–19 BODY – REAR BUMPER 12. REMOVE REAR BUMPER ARM (a) Remove 2 grommets. (6) Remove 2 bolts and the bumper arm_ REAR BUMPER INSTALLATION INSTALL REAR BUMPER PARTS BY FOLLOWING RE– MOVAL SEQUENCE IN REVERSE 1. INSTALL FOLLOWING PARTS: (a) Rear bumper arm Torque: 79 N–m (810 kgf–cm, 59 ft–lbf) (b) Rear bumper reinforcement Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) 2. INSTALL REAR BUMPER SIDE SUPPORT (a) Place the side support in the bumper cover. (b) Using a riveter, install 3 rivets. (c) Install 2 seal rubbers to 2 bolts. BO–20 BODY – HOOD HOOD HOOD ADJUSTMENT HINT: Since the centering bolt is used as the hood hinge and lock set bolt, the hood and lock cannot be adjusted with it on. Substitute the bolt with washer for the centering bolt. 1. ADJUST HOOD IN FORWARD / REARWARD AND LEFT/RIGHT DIRECTIONS Adjust the hood by loosening the hood side hinge bolts. Torque: 14 N–m (145 kgf–cm, 10 ft–lbf) 2. ADJUST FRONT EDGE OF HOOD IN VERTICAL DI– RECTIONS Adjust the hood by turning the cushions. 3. ADJUST HOOD LOCK (a) Adjust the lock by loosening the bolts. Torque: 7.8 N–m (80 kgf–cm, 69 in.–lbf) (b) Install radiator support upper seal with 10 clips. BO–21 BODY – FRONT DOOR FRONT DOOR COMPONENTS BO–22 BODY – FRONT DOOR COMPONENTS (Cont’d) BO–23 BODY – FRONT DOOR FRONT DOOR ADJUSTMENT 1. ADJUST DOOR IN FORWARD/ REARWARD AND VERTICAL DIRECTIONS Using SST, adjust the door by loosening the body side hinge bolts. SST 09812–00020 2. ADJUST DOOR IN LEFT/ RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust. HINT: Substitute the bolt with washer for the center– ing bolt. 3. ADJUST DOOR LOCK STRIKER (a) Check that the door fit and door lock linkages are adjusted correctly. (b) Loosen the striker mounting screws to adjust. (c) Using a plastic hammer, tap the striker to adjust it. FRONT DOOR DISASSEMBLY 1. w/o Power Window: REMOVE REGULATOR HANDLE Pull off the snap ring with a shop rag and remove the regulator handle and plate. 2. REMOVE INSIDE HANDLE BEZEL (a) Using a screwdriver, pry out the bezel. HINT: Tape the screwdriver tip before use. (b) Pull the bezel rearwards to remove it. BO–24 BODY – FRONT DOOR 3. Coupe: REMOVE DOOR COURTESY LIGHT Remove the light by pulling, then disconnect the con– nector. 4. REMOVE DOOR TRIM Sedan, Wagon: HINT: Tape the screwdriver, remove tip before use. (a) Remove 2 clips. (b) Using a screwdriver, remove 2 screw caps and the tweeter cover. (c) Remove 6 screws. (d) Insert the screwdriver between the door and the door trim to pry out. (e) Pull the trim upwards to remove it, then disconnect the connector. (f) Remove the inner weatherstrip. (g) Remove 2 screws and the power window switch. (h) Remove 6 screws and the armrest. (i) Remove 2 screws and the lower speaker cover. (j) Remove the clip, 9 screws and the door pocket. Coupe: HINT: Tape the screwdriver tip before use. (a) Remove the 2 clips. (b) Using a screwdriver, remove the 3 caps and tweeter cover. (c) Remove 5 screws. (d) Insert the screwdriver between the door and the door trim to pry out. (e) Pull the trim upwards to remove it, then disconnect the connectors. (f) Remove the inner weatherstrip. (g) Remove 3 screws and power window switch. (h) Remove 3 screws and tweeter speaker. (i) Remove 2 screws and front speaker cover. (j) Remove 7 screws and door armrest. (k) Remove the trim support. (1) Remove 8 screws and door pocket. BO–25 BODY – FRONT DOOR 5. REMOVE REAR VIEW MIRROR (a) Remove the cover. (b) Remove 3 screws and the mirror. (c) w/ Remote Control Mirror: Disconnect the connector. 6. REMOVE DOOR INSIDE HANDLE (a) Disconnect 2 links. (b) Remove 3 screws and the handle. 7. REMOVE SPEAKER (a) Remove 4 screws and the speaker. (b) Disconnect the connector. 8. REMOVE SERVICE HOLE COVER 9. REMOVE DOOR GLASS RUN Pull the glass run upwards and remove it. 10. REMOVE FRONT DOOR BELT MOULDING Pry out the clips from the edge of the weatherstrip and remove the moulding. 11. REMOVE FRONT DOOR FRAME MOULDING (a) Sedan, Wagon: Remove 3 screws and the moulding. (b) Coupe: Remove 3 screws. (c) Pry out the clips and remove the moulding. 12. REMOVE FRONT DOOR UPPER MOULDING (a) Sedan, Wagon: Remove 7 screws. BO–26 BODY – FRONT DOOR (b) Coupe: Remove 9 screws. (c) Pry out the clip and remove the moulding. 13. REMOVE DOOR GLASS HINT: Insert a shop rag inside the panel to prevent scratching the glass. (a) Remove 2 glass mounting bolts. (b) Remove the door glass by pulling it upwards. 14. REMOVE FRONT DOOR WEATHERSTRIP While pulling the weatherstrip by hand, remove the clips using a clip remover. HINT: Do not pull stronger on the weatherstrip as it may tear. 15. Sedan, Wagon: REMOVE DOOR INSIDE PANEL FRAME (a) Remove 4 nuts. (b) Remove 3 bolts and the frame. 16. REMOVE WINDOW REGULATOR Sedan, Wagon: (a) Remove 2 nuts. (b) w/ Power Window: Disconnect the connector. (c) Remove the regulator through the service hole. BO–27 BODY – FRONT DOOR Coupe: (a) Remove 4 nuts and 3 bolts. (b) w/ Power Window: Disconnect the connector. (c) Remove the regulator through the service hole. 17. REMOVE FRONT LOWER FRAME Remove the nut, 2 bolts and the frame. 18. REMOVE REAR LOWER FRAME Remove the nut, the bolt and the frame. 19. REMOVE DOOR LOCK (a) Remove 2 clips. (b) Disconnect 2 links from the door lock and remove 2 links. (c) Disconnect 2 links from the outside handle and the lock cylinder. (d) Remove 3 screws. (e) w/ Power Door Lock: Disconnect the connector. (f) Remove the door lock through the service hole. 20. REMOVE OUTSIDE HANDLE (a) Remove the hole plug. (b) Remove 2 bolts and the outside handle with the lock cylinder. 21. REMOVE DOOR LOCK CYLINDER Remove the bolt and the lock cylinder from the out– side handle. BO–28 BODY – FRONT DOOR FRONT DOOR ASSEMBLY 1. BEFORE INSTALLING PARTS, COAT THEM WITH MP GREASE (a) Apply MP grease to the window regulator rollers. (b) Apply MP grease to the sliding surface of the door lock. 2. INSTALL DOOR LOCK CYLINDER Install the lock cylinder with the bolt to the outside handle. BO–29 BODY – FRONT DOOR 3. INSTALL OUTSIDE HANDLE (a) Install the outside handle with 2 bolts. (b) Install hole plug. 4. INSTALL DOOR LOCK (a) Apply adhesive to 3 screws. Part No.08833–00070, THREE BOND 1324 or equivalent (b) Install the lock with 3 screws. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) (c) w/ Power Door Lock: Connect the connector. (d) Connect 2 links to the outside handle and the door lock cylinder. (e) Connect 2 links to the door lock. (f) Install 2 clips. 5. INSTALL FRONT LOWER FRAME Install the frame with the nut and 2 bolts. 6. INSTALL REAR LOWER FRAME Install the frame with the nut and the screw. 7. INSTALL WINDOW REGULATOR Sedan. Wagon: (a) Place the regulator through the service hole. (b) w/ Power Window: Connect the connector. (c) Install the regulator with 2 riuts. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) Coupe: (a) Install the regulator through the service hole. (b) w/ Power Window: Connect the connector. (c) Install the 3 nuts and the 3 bolts. BO–30 BODY – FRONT DOOR 8. Sedan, Wagon: INSTALL DOOR INSIDE PANEL (a) Install the frame with the 3 bolts. (b) Install the 4 nuts. Torque: 5.4 N–m (55 kgf–cm, 48in.–lbf) 9. INSTALL FRONT DOOR WEATHERSTRIP Push down on the clips of the weatherstrip. 10. INSTALL DOOR GLASS HINT: Insert a shop rag inside the panel to prevent scratching the glass. (a) Insert the glass to the frame. (b) Temporarily tighten 2 glass mounting bolts. 11. INSTALL FRONT DOOR UPPER MOULDING (a) Sedan, wagon: Install the moulding with the 7 screws. (b) Coupe: Install the moulding with the 9 screws. 12. INSTALL FRONT DOOR FRAME MOULDING Install the moulding with the 3 screws and the nut. 13. INSTALL FRONT DOOR BELT MOULDING Install the claw of the clips into the upper panel slit and push the moulding onto the panel. 14. INSTALL DOOR GLASS RUN Insert the glass run to the door frame. BO–31 BODY – FRONT DOOR 15. ADJUST DOOR GLASS Adjust the glass and tighten when dimension A and B, as shown, are equal. HINT: Substitute the bolt with washer for the center– ing bolt. 16. INSTALL SERVICE HOLE COVER Seal the service hole cover with adhesive. HINT: Bring out the links through the service hole cover. 17. INSTALL DOOR INSIDE HANDLE (a) Install the handle with 3 screws. (b) Connect the 2 links. 18. INSTALL SPEAKER Install the speaker with 4 screws, then connect the connector. 18. INSTALL REAR VIEW MIRROR (a) w/ Remote Control Mirror: Connect the connector. (b) Install the mirror with 3 screws. (c) Install the cover. 20. INSTALL DOOR TRIM Sedan, Wagon: (a) Install the door pocket with the clip and 9 screws. (b) Install the lower speaker cover with 2 screws. (c) Install the armrest with 6 screws. (d) Install the power window switch with 2 screws. (e) Install the inner weatherstrip. BO–32 BODY – FRONT DOOR (f) Insert the upper edge of the trim from above, tap the trim by hand, fix it in place with the clips, then connect the connectors. (g) Install the 6 screws. (h) Install the 2 screw caps and the tweeter cover. (i) Install the 2 clips. Coupe: (a) Install the 8 screws and door pocket. (b) Install the door trim support. (c) Install the 7 screws and door armrest. (d) Install the 2 screws and door speaker cover. (e) Install the 3 screws and tweeter speaker. (f) Install the 3 screws and power window switch. (g) Install the inner weatherstrip. (h) Insert the upper edge of the trim from above, tap the trim by hand, fix it in place with the clips, then connect the connector. (i) Install the 5 screws. (j) Install the 3 caps and tweeter cover. (k) Install the 2 clips. 21. Coupe: INSTALL DOOR COURTESY LIGHT Tap the light to install it, then connect the connector. 22. INSTALL INSIDE HANDLE BEZEL Tap the bezel to install it. BO–33 BODY – FRONT DOOR 23. INSTALL REGULATOR HANDLE With door window fully closed, install the plate and the regulator handle with the snap ring, as shown. BO–34 BODY – REAR DOOR REAR DOOR COMPONENTS BO–35 BODY – REAR DOOR COMPONENTS (Cont’d) BO–36 BODY – REAR DOOR REAR DOOR ADJUSTMENT 1. ADJUST DOOR IN FORWARD/ REARWARD AND VERTICAL DIRECTIONS (a) Remove rear seat cushion and rear seat back. (b) Sedan: Remove roof side inner garnish. (c) Sedan: Remove rear seat side garnish. (d) Sedan: Remove front door inside scuff plate. (e) Remove center pillar lower garnish. (f) Loosen the body side hinge nuts to adjust. (g) Install center pillar lower garnish. (h) Sedan: Install front door inside scuff plate. (i) Sedan: Install rear seat side garnish. (j) Sedan: Install roof side inner garnish. (k) Install rear seat back and rear seat cushion. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) BO–37 BODY – REAR DOOR 2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust. HINT: Substitute the bolt with washer for the center– ing bolt. 3. ADJUST DOOR LOCK STRIKER (a) Check that the door fit and door lock linkages are adjusted correctly. (b) Loosen the striker mounting screws to adjust. (c) Using a plastic hammer, tap the striker to adjust it. REAR DOOR DISASSEMBLY 1. w/o Power Window: REMOVE REGULATOR HANDLE Pull off the snap ring with a shop rag and remove the regulator handle and plate. 2. w/ Power Window: REMOVE POWER WINDOW SWITCH Using a screwdriver, remove the switch, then discon– nect the connector. HINT: Tape the screwdriver tip before use. 3. REMOVE INSIDE HANDLE BEZEL (a) Using a screwdriver, pry out the bezel. HINT: Tape the screwdriver tip before use. (b) Pull the bezel rearwards to remove it. BO–38 BODY – REAR DOOR 4. REMOVE DOOR TRIM HINT: Tape the screwdriver tip before use. (a) Remove 4 clips. (b) Using a screwdriver, remove the screw cap. (c) Remove 2 screws. (d) Insert the screwdriver between the door and the door trim to pry out. (e) Pull the trim upwards to remove it then disconnect the connector. (f) Remove the inner weatherstrip. (g) Remove 6 screws and the armrest. 5. REMOVE DOOR INSIDE HANDLE (a) Disconnect 2 links. (b) Remove 3 screws and the handle. 6. REMOVE SERVICE HOLE COVER (a) w/ Power Window: Using a clip remover, remove 2 screw grommets. w/o Power Window: Using a clip remover, remove 3 screw grommets. (b) Remove service hole cover. 7. REMOVE DOOR GLASS RUN Pull the glass run upwards to remove it. BO–39 BODY – REAR DOOR 8. REMOVE REAR DOOR BELT MOULDING Pry out the clips from the edge of the weatherstrip and remove the moulding. 8. Sedan: REMOVE DOOR GLASS DIVISION BAR (a) Remove the screw. (b) Remove 2 bolts and the division bar. 10. Wagon: REMOVE REAR LOWER FRAME (a) Remove the cover. (b) Remove nut. (c) Remove bolt and frame. 11. REMOVE DOOR GLASS HINT: Insert a shop rag inside the panel to prevent scratching the glass. (a) Remove 2 glass mounting bolts. (b) Remove the door glass by pulling it upwards. 12. Sedan: REMOVE QUARTER WINDOW GLASS WITH WEA– THERSTRIP (a) Remove the quarter window glass together with the weatherstrip by pulling it forwards. (b) Remove the weatherstrip from the quarter window glass. BO–40 BODY – REAR DOOR 13. Wagon: REMOVE REAR DOOR FRAME MOULDING (a) Remove 2 screws and nut. (b) Pry out the clips and remove the moulding. 14. REMOVE REAR DOOR FRAME MOULDING (a) Remove 3 screws. (b) Pry out the clips and remove the moulding. 15. REMOVE REAR DOOR UPPER MOULDING (a) Sedan: Remove the clip. (b) Remove 5 screws and the moulding. (c) Wagon: Remove 3 screws and the moulding. 16. REMOVE REAR DOOR WEATHERSTRIP While pulling the weatherstrip by hand, remove the clips using a clip remover. HINT: Do not pull strongly on the weatherstrip as it may tear. BO–41 BODY – REAR DOOR 17. REMOVE DOOR INSIDE PANEL FRAME (a) Remove 4 nuts. (b) Remove 3 bolts and the frame. 18. REMOVE WINDOW REGULATOR (a) Remove 2 nuts. (b) w/ Power Window: Disconnect the connector. (c) Remove the regulator through the service hole. 19. REMOVE CHILD PROTECTOR LOCK LEVER KNOB Using a screwdriver, remove the knob. HINT: Tape the screwdriver tip before use. 20. REMOVE DOOR LOCK (a) Remove the clip. (b) Disconnect 2 links from the door lock and remove 2 links. (c) Remove 3 screws. (d) w/ Power Door Lock: Disconnect the connector. (e) Remove the door lock through the service hole. 21. REMOVE OUTSIDE HANDLE Remove 2 bolts and the outside handle. BO–42 BODY – REAR DOOR POWER WINDOW MOTOR REMOVAL AND INSTALLATION 1. REMOVE POWER WINDOW MOTOR (a) Remove the cover plate by bending its tabs. (b) Pull out the drum while detaching the cable guide out from the motor. HINT: • Pull out the drum and the cable guide evenly without tilting the drum. • Handle the window regulator carefully so that the cable does not get detached. • Do not pry above parts with a screwdriver. 2. INSTALL POWER WINDOW MOTOR (a) Install the motor by fitting the shaft of the motor into the window regulator drum. HINT: • If the shaft does not fit properly into the drum, slowly move the window glass bracket by hand to turn the drum. • While turning the drum, make sure that it does not detach away from the cable guide. (b) Reattach the cover plate. (c) Use a plastic hammer to bend the cover plate tabs. HINT: • Do not strike on the tabs with excessive force. • Attach the cover plate firmly onto the motor to eliminate any looseness. In case the cable detaches from the drum, it can be reattached as follows: (a) Attach the drum, cable guide, and regulator as shown. BO–43 BODY – REAR DOOR (b) Attach the compression spring onto the cable. (c) Attach the cable onto the cable guide. (d) Attach the cable onto the drum. HINT: Do not cross the cable ends. (e) Wrap the cable around the drum from the top. (f) Wrap the cable around the drum from the bottom. HINT: Do not flip the drum while wrapping the cable around it. (g) Before installing the drum into the guide, verify that the cable is not taut. HINT: Verify that the cable ends are not crossed. (h) Flip the drum over, and the cable will now be crossed. (i) Verify that the cable is wrapped properly in the groove. BO–44 BODY – REAR DOOR REAR DOOR ASSEMBLY 1. BEFORE INSTALLING PARTS, COAT THEM WITH MP GREASE (a) Apply MP grease to the window regulator rollers. (b) Apply MP grease to the sliding surface of the door lock. 2. INSTALL OUTSIDE HANDLE Install the outside handle with 2 bolts. 3. INSTALL DOOR LOCK (a) Apply adhesive to 3 screws. Part No.08833–00070, THREE BOND 1324 or equivalent (b) Install the door lock with 3 screws. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) (c) w/ Power Door Lock: Connect the connector. (d) Connect 2 links to the door lock. (e) Install the clip. 4. INSTALL CHILD PROTECTOR LOCK LEVER KNOB 5. INSTALL WINDOW REGULATOR (a) Place the regulator through the service hole. (b) w/ Power Window: Connect the connector. (c) Install the regulator with 2 nuts. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) BO–45 BODY – REAR DOOR 6. INSTALL DOOR INSIDE PANEL FRAME (a) Install the frame with 3 bolts. (b) Install 4 nuts. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) 7. INSTALL REAR DOOR WEATHERSTRIP Push down on the clips of the weatherstrip. 8. INSTALL REAR DOOR UPPER MOULDING (a) Sedan: Install the moulding with 5 screws and the clip. (b) Wagon: Install the moulding with 3 screws. 9. INSTALL REAR DOOR FRAME MOULDING (a) Sedan: Install the moulding with 3 screws. (b) Wagon: Install the moulding with 2 screws and nut. 10. Sedan: INSTALL QUARTER WINDOW GLASS WITH WEA– THERSTRIP (a) Install the weatherstrip to the quarter window glass. (b) Install the quarter window glass together with the weatherstrip. 11. Wagon: INSTALL REAR DOOR REAR FRAME MOULDING Install the moulding with 2 screws and nut. BO–46 BODY – REAR DOOR 12. INSTALL DOOR GLASS HINT: Insert a shop rag inside the panel to prevent scratching the glass. (a) Insert the glass to the frame. (b) Temporarily tighten 2 glass mounting bolts. 13. Sedan: INSTALL DOOR GLASS DIVISION BAR Install the division bar with 2 bolts and the screw. 14. Wagon: INSTALL REAR LOWER FRAME Install the frame with the bolt and screw. 15. INSTALL REAR DOOR BELT MOULDING Install the claw of the clips into the upper panel slit and push the moulding onto the panel. 16. INSTALL DOOR GLASS RUN Insert the glass run to the door frame. 17. ADJUST DOOR GLASS Adjust the glass and tighten when dimension A and B, as shown, are equal. HINT: Substitute the bolt with washer for the center– ing bolt. BO–47 BODY – REAR DOOR 18. INSTALL SERVICE HOLE COVER (a) Seal the service hole cover with adhesive. HINT: Bring out the links through the service hole cover. (b) w/ Power Window: Install 2 screw grommets. (c) w/o Power Window: Install 3 screw grommets. 19. INSTALL DOOR INSIDE HANDLE (a) Install the handle with 3 screws. (b) Connect 2 links. 20. INSTALL DOOR TRIM (a) Install the armrest with 6 screws. (b) Install the inner weatherstrip. (c) Insert the upper edge of the trim from above, tap the trim by hand fix it in place with the clips, then connect the connector. (d) Install 2 screws. (e) Install the screw cap. (f) Install 4 clips. 21. INSTALL INSIDE HANDLE BEZEL Tap the bezel to install it. 22. w/ Power Window: INSTALL POWER WINDOW SWITCH Tap the switch to install it, then connect the connec– tor. BO–48 BODY – REAR DOOR 23. INSTALL REGULATOR HANDLE With door window fully closed, install the plate and the regulator handle with the snap ring, as shown. BO–49 BODY – BACK DOOR BACK DOOR COMPONENTS BO–50 BODY – BACK DOOR BACK DOOR ADJUSTMENT 1. ADJUST DOOR IN FORWARD / REARWARD AND LEFT /RIGHT DIRECTIONS (a) Remove the rear header trim. (b) Loosen the body side hinge nuts to adjust. Torque: 13 N–m (130 kgf–cm, 9.4 ft–lbf) (c) Install the rear header trim. (d) Install the rear seat side cushion. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) 2. ADJUST DOOR IN LEFT /RIGHT AND VERTICAL DIRECTIONS Loosen the door side hinge bolts to adjust. Torque: 13 N–m (130 kgf–cm, 9.4 ft–lbf) 3. ADJUST DOOR LOCK STRIKER (a) Remove rear floor finish plate by pulling. (b) Loosen the striker mounting screws to adjust. (c) Using a plastic hammer, tap the striker to adjust it. (d) Install the rear floor finish plate. BO–51 BODY – BACK DOOR BACK DOOR DAMPER STAY NOTICE: Handling the damper. • Do not disassemble the damper because the cylinder is filled with pressurized gas. • If the damper is to be replaced, drill a 2.0 – 3.0 mm (0.079 – 0.118 in.) hole in the bottom of the re– moved damper cylinder to completely release the high–pressure gas before disposing of it. • When drilling, chips may fly out so work carefully. • The gas is colorless, odorless and non–toxic. • When working, handle the damper carefully. Never score or scratch the exposed part of the piston rod, and never allow paint or oil to get on it. • Do not turn the piston rod and cylinder with the damper fully extended. BACK DOOR DISASSEMBLY REMOVE FOLLOWING PARTS: (a) Rear wiper arms (b) w/ High Mount Stop Light: High mount stop light (c) Back door trim upper board (d) Back door trim cover LH BO–52 BODY – BACK DOOR (e) Back door trim cover RH (f) Back door inside handle bezel (g) Speaker cover and speaker (h) Back door trim board (i) Wiper motor and link (j) License plate light (k) Back door outside garnish (1) Back door outside handle (m) Rear combination lights (n) Back door control (o) Back door inside handle (p) Child protector lock (q) Door lock cylinder (r) Back door lock BACK DOOR ASSEMBLY ASSEMBLE BACK DOOR PARTS BY FOLLOWING DISASS– EMBLY SEQUENCE IN REVERSE BEFORE INSTALLING PARTS, COAT THEM WITH MP GREASE Apply MP grease to the sliding surface of the door lock control. BO–53 BODY – LUGGAGE COMPARTMENT LUGGAGE COMPARTMENT COMPONENTS BO–54 BODY – LUGGAGE COMPARTMENT LUGGAGE COMPARTMENT DOOR ADJUSTMENT 1. ADJUST DOOR IN FORWARD/ REARWARD AND LEFT/RIGHT DIRECTIONS (a) Remove rear seat cushion and rear seat back. (b) Remove roof side inner garnish. (c) Remove package tray trim garnish. (d) Remove package tray trim. (e) Loosen 2 body side hinge bolt to adjust. 2. ADJUST DOOR LOCK STRIKER (a) Remove the rear floor finish plate by pulling. (b) Remove the clips and the rear luggage trim. (c) Loosen the bolts to adjust. BO–55 BODY – LUGGAGE COMPARTMENT TORSION BAR REMOVAL AND INSTALLATION 1. REMOVE FOLLOWING PARTS: (a) Rear floor finish plate (b) Rear luggage trim (c) Right side luggage trim (d) Left side luggage trim 2. REMOVE TORSION BAR (a) Remove the torsion bar from center bracket. (b) Install SST to the torsion bar on the hinge side. SST 09804–24010 (c) Push down on SST, and pull the luggage compartment door hinge from the torsion bar. (d) Slowly lift SST, and remove the torsion bar from the torsion bar bracket with SST. (e) Remove the torsion bar. (f) Do the same for the other side. 3. INSTALL TORSION BAR (a) Insert the torsion bar into the bracket as shown. BO–56 BODY – LUGGAGE COMPARTMENT (b) Install SST to the torsion bar of the hinge side. SST 09804–24010 (c) Slowly lift the torsion bar with SST and place in the torsion bar bracket. (d) Slowly push down SST, and install the torsion bar to the hinge. (e) Slowly lift SST, and install the torsion bar. (f) Install the torsion bar to center bracket. (g) Do the same for the other side. 4. INSTALL FOLLOWING PARTS: (a) Left side luggage trim (b) Right side luggage trim (c) Rear luggage trim (d) Rear floor finish plate BO–57 BODY – WIPER AND WASHER WIPER AND WASHER COMPONENTS BO–58 BODY – WIPER AND WASHER COMPONENTS (Cont’d) BO–59 BODY – WIPER AND WASHER WIPER AND WASHER REMOVAL 1. REMOVE WIPER ARMS Remove 2 nuts and 2 wiper arms. 2. REMOVE COWL LOUVER (a) Using a clip remover, remove the clips and the weath– erstrip. (b) Pull out the cowl louver forwards as shown. 3. REMOVE WIPER MOTOR (a) Disconnect the connector, then unfasten 4 bolts and remove the motor. (b) Disconnect the wiper link. 4. REMOVE WIPER LINK (a) Remove 6 bolts. (b) Remove the wiper link through the service hole. 5. REMOVE WINDOW WASHER NOZZLE (a) Remove the cover. (b) Using a screwdriver, remove the nozzle. HINT: Tape the screwdriver tip before use. BO–60 BODY – WIPER AND WASHER WIPER AND WASHER INSTALLATION INSTALL FOLLOWING PARTS: (a) Window washer nozzle (b) Wiper link (c) Wiper motor (d) Wiper arms Torque: 19 N–m (195 kgf–cm. 14 ft–lbf) REAR WIPER REMOVAL 1. REMOVE,REAR WIPER ARMS (a) Remove 2 ’nuts and 2 wiper arms. (b) Remove 2 caps. (c) Remove 2 nuts and 2 washers. 2. REMOVE FOLLOWING PARTS: (a) Back door trim upper board (b) Back door trim board 3. REMOVE REAR WIPER MOTOR ASSEMBLY (a) Disconnect the connector, then unfasten 3 bolts. (b) Remove the motor assembly. (c) Remove the wiper link assembly. BO–61 BODY – WIPER AND WASHER REAR WIPER INSTALLATION ASSEMBLE REAR WIPER PARTS BY FOLLOWING RE– MOVAL SEQUENCE IN REVERSE INSTALL REAR WIPER ARM (a) Install 2 washers with 2 nuts. Torque: 11 N .m (110 kgf–cm, 8 ft–Ibf) (b) Install the wiper arm and operate the wiper once and turn the wiper switch OFF. (c) Adjust the installation position of the wiper arm to the position shown in the installation. (A) Approx. 20 mm (0.79 in.) (d) Torque the nut. Torque: 5.4 N–m (55 kgf–cm, 48in.–lbf) REAR WASHER NOZZLE ADJUSTMENT 1. INSPECT REAR WASHER NOZZLE While operating the washer, check whether the point where the washer fluid hits the back door glass and the upsurge area are with in the range indicated by the hatched line. (A)Approx. 600 mm (23.62 in.) (B)Approx. 200 mm (7.84 in.) 2. ADJUST FRONT WASHER NOZZLE Using a tool like that shown in the installation, change the direction of the nozzle hole to adjust the point where washer fluid strikes the windshield. BO–62 BODY – WINDSHIELD MOULDING WINDSHIELD MOULDING COMPONENTS WINDSHIELD MOULDING REMOVAL 1. REMOVE WEATHERSTRIP Remove the weatherstrip by pulling. 2. REMOVE WINDSHIELD OUTSIDE MOULDING Remove 3 screws and the moulding. BO–63 BODY – WINDSHIELD MOULDING 3. REMOVE WINDOWSHIELD UPPER MOULDING (a) Insert the top of scraper between the body and the moulding. HINT: Tape the scraper tip before use. (b) Pry up the scraper to loosen the moulding from the claws of the clips and retainers. (c) Remove the moulding. FASTENER REPLACEMENT REPLACE FASTENER (a) Remove the damaged fastener. (b) Cut off the old adhesive around the fastener installa– tion area. HINT: Be careful not to damage the body. (c) Clean the installation area. (d) Install a new fastener onto the body. WINDSHIELD MOULDING INSTALLATION 1. INSTALL NEW CLIP INTO MOULDING Install the clip to the appropriate place on the mould– ing, where the clip would engage with the fastener. 2. APPLY ADHESIVE AT NEW CLIP INSTALLATION AREA (a) When the clip being engaged with the moulding is removed, cut out the old adhesive around the clip installation area. NOTICE: Do not damage the body and fastener. (b) Apply adhesive at the clip installation area so water does not collect there. 3. INSTALL WINDSHIELD UPPER MOULDING (a) Place the moulding onto the body. (b) Tap the moulding with your hand to fasten the clips at the glassedge. At the same time, install the fastener, by tapping them by hand. 4. INSTALL WINDSHIELD OUTSIDE MOULDING 5. INSTALL WEATHERSTRIP BO–64 BODY – BODY OUTSIDE MOULDING BODY OUTSIDE MOULDING COMPONENTS BO–65 BODY – BODY OUTSIDE MOULDING FRONT DOOR BELT AND FRAME MOULDING REMOVAL AND INSTALLATION 1. REMOVE FRONT DOOR COMPONENT PARTS (See steps 1 to 5 and 9 pages BO–23 to 25) 2. REMOVE FRONT DOOR BELT MOULDING (See step 10 on page BO–25) 3. REMOVE FRONT DOOR FRAME MOULDING (See step 11 on page BO –25) 4. REMOVE FRONT DOOR UPPER MOULDING (See step 12 on page BO–25 to 26) 5. INSTALL FOLLOWING PARTS: (See steps 11 to 14 and 19 to 23 on pages BO–30 to 33) (a) Front door upper moulding (b) Front door frame moulding (c) Front door belt moulding (d) Front door component parts REAR DOOR BELT AND FRAME MOULDING REMOVAL AND INSTALLATION 1. REMOVE REAR DOOR COMPONENT PARTS (See steps 1 to 4 on pages BO–37 to 38) 2. REMOVE REAR DOOR BELT MOULDING (See step 8 on page BO–39) 3. REMOVE REAR DOOR COMPONENT PARTS (See steps 5 to 7 and 9 to 12 on pages BO–38 to 39) 4. REMOVE REAR DOOR FRAME MOULDING (See step 14 on page BO–40) 5. REMOVE REAR DOOR UPPER MOULDING (See step 15 on page BO–40) 6. INSTALL FOLLOWING PARTS: (a) Rear door upper moulding (b) Rear door frame moulding (c) Rear door belt moulding (d) Rear door component parts BO–66 BODY – BODY OUTSIDE MOULDING SIDE PROTECTION MOULDING REMOVAL Precautions for storing moulding material: • Store in a cool place, avoiding direct sunlight, high temperature and dust. • The moulding is of polyvinyl chloride, so do not allow it to come in contact with thinner or other solvents, open flame, or boiling water. • The storage time for the moulding and adhesive is limited to about 9 months. 1. REMOVE ENDS OF MOULDING Using a scraper, pry the moulding loose about 30 mm (1.18 in.) from the ends. HINT: Tape the scraper tip before use. 2. REMOVE MOULDING AND ADHESIVE (a) Pull oft the moulding by cutting the adhesive with a knife. (b) Scrape oft adhesive from the body with sandpaper cutter. NOTICE: • Remember that 30–80 mm (1.18–3.15 in.) of the ends of the moulding are glued tightly with a strong adhesive. • Do not reuse moulding. SIDE PROTECTION MOULDING INSTALLATION 1. CLEAN MOULDING MOUNTING SURFACE Wipe off stains with cleaner. 2. HEAT BODY MOUNTING SURFACE Using a heat light, heat the body mounting surface to 40 – 60
C (104 –140
F). NOTICE: When the moulding is installed, the temperature of the mounting surface should be 20* C (68
F) or higher. BO–67 BODY – BODY OUTSIDE MOULDING 3. HEAT MOULDING Using a heat light, heat the moulding to 20 – 30
C (68
– 86
F) NOTICE: Do not heat moulding excessively. The temperature should not be higher than 80
C (176
F). 4. APPLY ADHESIVE TO DOOR OUTSIDE MOULDING Apply adhesive to both punched out ends of the moulding. NOTICE: Install the moulding within 30 minutes after applying the adhesive. Part No. 08850–00051 5. LIFT MOULDING RELEASE SHEET FROM FACE OF MOULDING NOTICE: When the moulding release sheet is removed, be sure that no dirt or dust can get onto the uncoverd area. 6. INSTALL MOULDING Align the bosses an the moulding with the body holes, and push the moulding to the body. NOTICE: • Be sure that the body and moulding are heated to the proper temperature. • Do not depress the adhesive – coated parts ex– cessively just hold them down with your thumb. • Scrape off any overflowing adhesive with a plastic spatula and clean the surface with a dry rag. • After installation, do not wash the vehicle for 24 hours. BO–68 BODY – BODY OUTSIDE MOULDING OUTSIDE LOWER MOULDING REMOVAL AND INSTALLATION 1. REMOVE FRONT FENDER LOWER MOULDING (a) Remove the screw. (b) Pry out the clip and remove the moulding. 2. REMOVE FRONT DOOR LOWER MOULDING (a) Remove 2 hole plugs. (b) Remove 2 nuts. (c) Pry out the clips and remove the moulding. 3. REMOVE REAR DOOR LOWER MOULDING (a) Remove 2 hole plugs. (b) Remove 2 nuts. (c) Pry out the clips and remove the moulding. 4. INSTALL FOLLOWING PARTS: (a) Front fender lower moulding (b) Front door lower moulding (c) Rear door lower moulding ROCKER PANEL MOULDING REMOVAL AND INSTALLATION 1. REMOVE ROCKER PANEL MOULDING (a) Remove 3 screws. (b) Pry out the clips and remove the moulding. 2. INSTALL ROCKER PANEL MOULDING REAR DOOR BELT AND FRAME MOULDING REMOVAL AND INSTALLATION 1. REMOVE REAR DOOR COMPONENT PARTS BO–69 BODY – BODY OUTSIDE MOULDING 2. REMOVE REAR DOOR BELT MOULDING Pry out the clips from the edge of the weatherstrip and remove the moulding. 3. REMOVE REAR DOOR REAR FRAME MOULDING (a) Remove 2 screws and the nut. (b) Pry out the clips and remove the moulding. 4. REMOVE REAR DOOR FRONT FRAME MOULDING (a) Remove 3 screws and the nut. (b) Pry out the clips and remove the moulding. 5. REMOVE REAR DOOR UPPER MOULDING Remove 3 screws and the moulding. 6. INSTALL FOLLOWING PARTS: (a) Rear door upper moulding (b) Rear door front frame moulding (c) Rear door rear frame moulding (d) Rear door belt moulding (e) Rear door component parts BO–70 BODY – BODY OUTSIDE MOULDING QUARTER WINDOW MOULDING REMOVAL AND INSTALLATION 1. REMOVE QUARTER WINDOW FRONT MOULDING Pry out the clips and remove the moulding. 2. REMOVE QUARTER WINDOW UPPER MOULDING Pry out the clips and remove the moulding. 3. REMOVE QUARTER WINDOW REAR MOULDING Pry out the clips and remove the moulding. 4. REMOVE QUARTER WINDOW BELT MOULDING Pry out the clips and remove the moulding. 5. INSTALL FOLLOWING PARTS: (a) Quarter window belt moulding (b) Quarter window rear moulding (c) Quarter window upper moulding (d) Quarter window front moulding BO–71 BODY – BACK WINDOW MOULDING BACK WINDOW MOULDING COMPONENTS BACK WINDOW MOULDING REMOVAL 1. REMOVE BACK WINDOW LOWER MOULDING Using a scraper, pry off the moulding from the clips and remove the moulding. HINT: Tape the scraper tip before use. 2. REMOVE BACK WINDOW MOULDING Using a knife, cut off the moulding as shown. NOTICE: Do not damage the body with the knife. BO–72 BODY – BACK WINDOW MOULDING BACK WINDOW MOULDING INSTALLATION 1. CUT ADHESIVE AT MOULDING INSTALLATION AREA Using the knife, cut off the adhesive around the mou– Iding installation area. 2. APPLY ADHESIVE AT MOULDING INSTALLATION AREA 3. INSTALL BACK WINDOW MOULDING Place the moulding onto the body and tap it by hand. 4. INSTALL BACK WINDOW LOWER MOULDING Place the moulding onto the body and tap it by hand. BO–73 BODY – BACK DOOR MOULDING BACK DOOR MOULDING COMPONENTS BO–74 BODY – BACK DOOR MOULDING BACK DOOR MOULDING REMOVAL REMOVE BACK DOOR MOULDING Using a knife, cut off the moulding as shown. NOTICE: Do not damage the body with the knife. BACK DOOR MOULDING INSTALLATION 1. CUT ADHESIVE AT MOULDING INSTALLATION AREA Using the knife, cut off the adhesive around the mou– lding installation area. 2. APPLY ADHESIVE AT MOULDING INSTALLATION AREA 3. INSTALL BACK DOOR MOULDING Place the moulding onto the body and tap it by hand. BO–75 BODY – WINDSHIELD WINDSHIELD COMPONENTS BO–76 BODY – WINDSHIELD WINDSHIELD REMOVAL 1. REMOVE FOLLOWING PARTS: (a) Inner rear view mirror (b) Sunvisors and holders (c) Front assist grip (d) Interior light 2. REMOVE FRONT PILLAR GARNISH (a) Sedan, Wagon: Remove the clips by your hand. (b) Sedan, Wagon: Pull the garnish rearwards to remove it. (c) Coupe: Rear side garnish must be removed before front piller garnish. 3. REMOVE HOOD 4. REMOVE FOLLOWING PARTS: (a) Wiper arms (b) Cowl louver 5. REMOVE WEATHERSTRIP Remove the weatherstrip by pulling. 6. REMOVE WINDSHIELD OUTSIDE MOULDING Remove 3 screws and the moulding. 7. REMOVE WINDSHIELD UPPER MOULDING (a) Insert the top of scraper between the body and the moulding. HINT: Tape the scraper tip before use. (b) Pry up the scraper to loosen the moulding from the claw of the clips and retainers. (c) Remove the moulding. BO–77 BODY – WINDSHIELD 8. REMOVE WINDSHIELD GLASS (a) Push piano wire through from the interior. (b) Tie both wire ends to a wooden block or like object_ HINT: Apply adhesive tape to the outer surface to keep the surface from being scratched. NOTICE: When separating the glass, take care not to damage the paint and interior and exterior ornaments. To prevent scratching the safety pad when removing the w indshield, place a plastic sheet between the piano wir– eand safety pad. (c) Cut the adhesive by pulling the piano wire around it. (d) Remove the glass. NOTICE: Leave as much of the adhesive on the body as possible when cutting off the glass. WINDSHIELD INSTALLATION 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY (a) Using a knife, cut away any rough areas on the body. HINT: Leave as much of the adhesive on the body as possible. (b) Clean the cutting surface of the adhesive with a piece of shop rag saturated in cleaner. HINT: Even if all the adhesive has been removed, clean the body. 2. REPLACE FASTENER (a) Remove the damaged fastener. (b) Cut off the old adhesive around the fastener installa– tion area. HINT: Be careful not to damage the body. (c) Clean the installation area. (d) Install a new fastener onto the body. 3. CLEAN REMOVED GLASS (a) Using a scraper, remove the adhesive sticking to the glass. (b) Clean the glass with cleaner. NOTICE: Do not touch the glass after cleaning it. BO–78 BODY – WINDSHIELD 4. INSTALL RETAINER Install the retainers as shown. 5. INSTALL SPACER 6. POSITION GLASS (a) Place glass in correct position. (b) Check that all contacting parts of the glass rim are perfectly even and do not make contact with the fasteners. (c) Place reference marks between the glass and body. (d) Remove the glass. 7. CLEAN CONTACT SURFACE OF GLASS Using a cleaner, clean the contact surface black– colored area around the entire glass rim. NOTICE: Do not touch the glass face after cleaning it. 8. INSTALL DAM Install the dam with double–stick tape as shown in the illustration. NOTICE: Do not touch the glass face after cleaning it. BO–79 BODY – WINDSHIELD 9. COAT CONTACT SURFACE OF BODY WITH PRIMER ”M” Using a brush, coat the contact surface on the body with Primer M. NOTICE: • Let the primer coating dry for 3 minutes or more. • Do not coat to the adhesive. • Do not keep any of the opened primer M and G for later use. 10. COAT CONTACT SURFACE OF GLASS WITH PRIMER ”G” (a) Using a brush or sponge, coat the edge of the glass and the contact surface with Primer G. (b) Before the Primer dries, wipe it off with a clean shop rag. NOTICE: Let the primer coating dry for 3 minutes or more. 11. MIX ADHESIVE COATING NOTICE: • Be sure that installation of the moulding is finished within usable time. (See step 3 on page BO–9) • The mixture should be made in 5 minutes or less. (a) Thoroughly clean the glass plate and putty spatula with solvent. (b) Thoroughly mix 500 g (117.64 oz.) of the main agent and 75 g (2.65 oz.) of the hardening agent on a glass plate or like object with a putty spatula. 12. APPLY ADHESIVE (a) Cut off the tip of the cartridge nozzle. Fill the cartridge with adhesive. (b) Load the cartridge into the sealer gun. (c) Coat the glass with adhesive as shown. BO–80 BODY – WINDSHIELD (d) Coat the body with adhesive as shown. 13. INSTALL GLASS HINT: Confirm that the dam is attached the body panel as shown in the illustration. (a) Position the glass so that the reference marks are lined up, and press in gently along the rim. (b) Using a spatula, apply adhesive on the glass rim. (c) Use a scraper to remove any excess or protruding adhesive. (d) Fasten glass securely until the adhesive sets. BO–81 BODY – WINDSHIELD 14. INSPECT FOR LEAKS AND REPAIR (a) Perform a leak test after the hardening time has ela– psed. (b) Seal any leak with auto glass sealer. Part No. 08833–00030 15. INSTALL WINDSHIELD UPPER MOULDING (a) Place the moulding onto the body. (b) Tap the moulding with your hand to fasten the clips at the glass edge. At the same time, install the fastener, by tapping them by hand. 16. INSTALL WINDSHIELD OUTSIDE MOULDING 17. INSTALL WEATHERSTRIP 18. INSTALL FOLLOWING PARTS: (a) Cowl louver (b) Wiper arms (c) Hood (d) Front pillar garnish (e) Interior light (f) Front assist grip (g) Sunvisors and holders (h) Inner rear view mirror BO–82 BODY – BACK WINDOW GLASS BACK WINDOW GLASS COMPONENTS BO–83 BODY – BACK WINDOW GLASS BACK WINDOW GLASS REMOVAL 1. REMOVE REAR SEAT CUSHION AND SEAT BACK 2. REMOVE ROOF SIDE INNER GARNISH (a) Remove the clips. (b) Remove the garnish by pulling. 3. w/o Rear Spoiler: REMOVE HIGH MOUNT STOP LIGHT (a) Remove the cover. (b) Remove 2 bolts and the stop light, then disconnect the connector. 4. REMOVE PACKAGE TRAY GARNISH Remove the garnish by pulling. 5. REMOVE PACKAGE TRAY TRIM (a) Remove 2 screw caps. (b) Remove 2 screws. (c) Remove the trim by pulling forwards. 6. REMOVE FOLLOWING PARTS: (a) Assist grips. (b) Rear side of roof headlining. 7. DISCONNECT DEFOGGER WIRE CONNECTORS 8. REMOVE SACK WINDOW LOWER MOULDING Using a scraper, pry off the moulding from the clips and remove the moulding. HINT: Tape the screwdriver tip before use. BO–84 BODY – BACK WINDOW GLASS 9. REMOVE BACK WINDOW MOULDING Using a knife, cut off the moulding as shown. NOTICE: Do not damage the body with the knife. 10. REMOVE BACK WINDOW GLASS Remove the glass in the same manner as windshield. (See step 8 on page BO–77) 11. REMOVE RETAINERS Remove retainers from the body. BACK WINDOW GLASS INSTALLATION 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY (See step 1 on page BO–77) 2. REPLACE LOWER MOULDING CLIP (a) Remove the screw and the damaged clip. (b) Install the new clip with the screw. 3. CLEAN REMOVED GLASS (See step 3 on page BO–77) 4. REMOVE STOPPERS Using a knife, remove the stoppers. 5. POSITION GLASS (See step6 on page BO–77) 6. CLEAN CONTACT SURFACE OF GLASS (See step 7 on page BO–78) 7. INSTALL DAM Install the dam with double–stick tape as shown in the drawing. NOTICE: Do not touch the glass face after cleaning it. 8. COAT CONTACT SURFACE OF BODY WITH PRIMER ’M’ (See step 9 on page BO–79) BO–85 BODY – BACK WINDOW GLASS 9. COAT CONTACT SURFACE OF GLASS WITH PRIMER ’G” (SEE STEP 10 ON PAGE BO–79) 10. MIX ADHESIVE COATING (SEE STEP 11 ON PAGE BO–79) 11. APPLY ADHESIVE (SEE STEP 12 ON PAGE BO–79) 12. INSTALL GLASS (SEE STEP 13 ON PAGE BO–80) 13. INSTALL BACK WINDOW MOULDING Place the moulding onto the body and tap it by hand. 14. INSTALL BACK WINDOW LOWER MOULDING Place the moulding onto the body and tap it by hand. 15. INSPECT FOR LEAKS AND REPAIR (SEE STEP 14 ON PAGE BO–81) 16. CONNECT DEFOGGER WIRE CONNECTORS 17. INSTALL FOLLOWING PARTS: (a) Rear side of roof headlining (b) Assist grips (c) Package tray trim (d) Package tray trim garnish (e) w/o Rear Spoiler: High mount stop light (f) Roof side inner garnish (g) Rear seat back and seat cushion Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) BO–86 BODY – QUARTER WINDOW GLASS QUARTER WINDOW GLASS COMPONENTS BO–87 BODY – QUARTER WINDOW GLASS COMPONENTS (Cont’d) BO–88 BODY – QUARTER WINDOW GLASS QUARTER WINDOW GLASS REMOVAL Coupe: 1. REMOVE REAR SEAT CUSHION 2. REAR SIDE SEAT BACK 3. REMOVE FOLLOWING PARTS: (a) Front seat outer belt shoulder anchor (b) Front seat outer belt bezel (c) Rear seat outer belt anchor (d) Roof side inner garnish. (e) Front door scuff plate. (f) Quarter trim board. (g) Front door weatherstrip. 4. REMOVE QUARTER WIND GLASS (a) Remove 5 nuts. (b) Using a knife, cut loose the adhesive. (c) Remove glass. NOTICE: Do not damege the body. BO–89 BODY – QUARTER WINDOW GLASS QUARTER WINDOW GLASS REMOVAL Wagon: 1. REMOVE REAR HEADER TRIM Remove the trim by pulling, then disconnect the con– nector. 2. REMOVE REAR FLOOR FINISH PLATE (a) Remove 2 cushions. (b) Remove 6 covers and 6 screws. (c) Remove the plate. 3. REMOVE FOLLOWING PARTS: Right Side: (a) Rear side seatback RH (b) w/ Third Seat: Spare wheel cover (c) Tonneau side cover RH (d) Deck trim side panel RH BO–90 BODY – QUARTER WINDOW GLASS (e) w/ Third Seat: Deck side rear garnish (f) Roof side inner garnish RH Left Side: (a) Rear side seatback LH (b) Tonneau side cover LH (c) Deck trim side panel LH (d) Roof side inner garnish LH BO–91 BODY – QUARTER WINDOW GLASS 4. REMOVE QUARTER WINDOW FRONT MOULDING Pry out the clips and remove the moulding. 5. REMOVE QUARTER WINDOW UPPER MOULDING Pry out the clips and remove the moulding. 6. REMOVE QUARTER WINDOW REAR MOULDING Pry out the clips and remove the moulding. 7. REMOVE QUARTER WINDOW BELT MOULDING Pry out the clips and remove the moulding. 8. REMOVE QUARTER WINDOW GLASS (a) Remove 9 nuts. (b) Using a knife, cut loose the adhesive. (c) Remove glass. NOTICE: Do not damage the body. QUARTER WINDOW GLASS INSTALLATION Coupe: 1. CLEAN BODY OR GLASS Wipe off any adhesive left on the body and glass with cleaner. 2. INSTALL QUARTER WINDOW GLASS (a) Apply adhesive at glass installation area. (b) Install the glass to the body. (c) Install 5 nuts. BO–92 BODY – QUARTER WINDOW GLASS 3. INSTALL FOLLOWING PARTS: (a) Front door weatherstrip. (b) Quarter trim board (c) Front door scuff plate (d) Roof side inner garnish (e) Rear seat outer belt anchor Torque: 43 N–m (440 kgf–cm. 32 ft–lbf) (f) Front seat outer belt bezel (g) Front seat outer belt shoulder anchor Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) (h) Rear side seat back Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) (i) Rear seat cushion QUARTER WINDOW GLASS INSTALLATION Wagon: 1. CLEAN BODY OR GLASS Wipe off any adhesive left on the body and glass with cleaner. 2. INSTALL QUARTER WINDOW GLASS (a) Apply adhesive at glass installation area. (b) Install the glass to the body. (c) Install 9 nuts. 3. INSTALL QUARTER WINDOW MOULDING (a) Install the quarter window belt moulding. (b) Install the quarter window rear moulding. (c) Install the quarter window upper moulding. (d) Install the quarter window front moulding. 4. INSTALL FOLLOWING PARTS: RIGHT SIDE: (a) Roof side inner garnish RH BO–93 BODY – QUARTER WINDOW GLASS (b) w/ Third Seat: Deck side rear garnish (c) Deck trim side panel RH (d) Tonneau side cover RH (e) w/ Third Seat: Spare wheel cover (f) Rear side seatback RH Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) Left Side: (a) Roof side inner garnish LH (b) Deck trim side panel LH (c) Tonneau side cover LH (d) Rear side seatback LH Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) BO–94 BODY – BACK DOOR GLASS BACK DOOR GLASS COMPONENTS BO–95 BODY – BACK DOOR GLASS BACK DOOR GLASS REMOVAL 1. REMOVE FOLLOWING PARTS: (a) Back door trim upper board (b) w/ High Mount Stop Light: High mount stop light (c) Back door trim cover LH (d) Back door trim cover RH 2. DISCONNECT DEFOGGER WIRE CONNECTORS 3. REMOVE BACK DOOR MOULDING Using a knife, cut off the moulding as shown. NOTICE: Do not damage the body with the knife. 4. REMOVE BACK DOOR GLASS (a) Remove 2 screws. (b) Remove the glass in the same manner as windshield. BO–96 BODY – BACK DOOR GLASS BACK DOOR GLASS INSTALLATION HINT: Install the glass in the same manner as the windshield. 1. CLEAN AND SHAPE CONTACT SURFACE OF BODY 2. CLEAN REMOVED GLASS 3. POSITION GLASS 4. CLEAN CONTACT SURFACE OF GLASS 5. COAT CONTACT SURFACE OF BODY WITH PRIM ER ”M” 6. COAT CONTACT SURFACE OF GLASS WITH PRIM ER ”G” 7. MIX ADHESIVE COATING 8. APPLY ADHESIVE 9. INSTALL GLASS 10. INSTALL BACK DOOR MOULDING Place the moulding onto the body and tap it by hand. 11. INSPECT FOR LEAKS AND REPAIR 12. CONNECT DEFOGGER WIRE CONNECTORS 13. INSTALL FOLLOWING PARTS: (a) Back door trim cover RH (b) Back door trim cover LH (c) w/ High Mount Stop Light: High mount stop light (d) Back door trim upper board BO–97 BODY – SLIDING ROOF SLIDING ROOF COMPONENTS BO–98 BODY – SLIDING ROOF ON–VEHICLE INSPECTION INSPECT SLIDING ROOF GLASS ALIGNMENT (a) Start the engine and check the operation time of the sliding roof. Operation time: Approx.6 sacs. (b) Check for abnormal noise or binding during operation. (c) With the sliding roof fully closed, check for water leakage. (d) Check for a difference in level between the sliding roof weatherstrip and roof panel. Front end: 1 ±1 mm (0.039±0.039 in.) Rear end: 0±1 mm (0±0.039 in.) If the sliding roof does not operate: (e) Remove the control switch cover. (f) Remove the large screw inside. NOTICE: Be careful not to lose the spring washer or shim. (g) Manually operate the moon roof by inserting a special crank–shaped screwdriver into the hole and turning the drive shaft. SLIDING ROOF ADJUSTMENT 1. REMOVE SLIDING ROOF GARNISHES Before making adjustments, remove the left and right sliding roof garnishes. HINT: After adjustment, reinstall the sliding roof gar– nishes. 2. TO ADJUST LEVEL DIFFERENCE Adjust by increasing or decreasing the number of shims between the bracket and sliding roof. BO–99 BODY – SLIDING ROOF 3. TO ADJUST FORWARD OR REARWARD (a) Adjust by loosening the sliding roof installation nuts, and move the sliding roof bracket forwards and back– wards. (b) When the front or rear alignment is not correct, remove the glass and adjust the drive rail. (c) Using a screwdriver, slide the link forwards or back– wards to align the 2 marks as shown. 4. TO ADJUST RIGHT OR LEFT Adjust by loosening the sliding roof rear shoe installa– tion nuts, and move the sliding roof to the right and left. 5. TO ADJUST CLEARANCE (Difference in left and right clearance) BO–100 BODY – SLIDING ROOF Adjust by loosening the sliding roof installation nuts and readjust the sliding roof to the proper position. SLIDING ROOF REMOVAL 1. DISCONNECT BATTERY CABLE FROM NEGATIVE TERMINAL CAUTION: Work must be started after. 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE SLIDING ROOF SWITCH (a) Using a screwdriver, remove the cover. HINT: Tape the screw driver tip before use. (b) Remove 2 screws and the switch, then disconnect the connectors. 3. REMOVE FOLLOWING PARTS: (a) Inner rear view mirror (b) Sunvisors and holders (c) Front assist grip 4. REMOVE FRONT PILLAR GARNISH (a) Sedan, Wagon: Remove the 2 clips by hand. (b) Sedan, Wagon: Pull the garnish rearwards to remove it. (c) Coupe: Rear side garnish must be removed before front piller garnish. 5. REMOVE FRONT SIDE OF ROOF HEADLINING (a) Disconnect the front side of roof headlining from the front side of housing. (b) Pull down the front side of roof headlining by hand. BO–101 BODY – SLIDING ROOF 2 6. REMOVE SLIDING ROOF CONTROL RELAY (a) Disconnect the connector. (b) Remove the bolt, the connector and the relay. 7. REMOVE DRIVE GEAR (a) Disconnect the connectors. (b) Remove 3 bolts and the drive gear. 8. REMOVE SIDE GARNISH Using a screwdriver, remove the garnishes. HINT: Tape the screwdriver tip before use. 9. REMOVE SLIDING ROOF GLASS (a) Remove 6 nuts and shims. HINT: Make sure of the number of shims. (b) Pull the glass upwards to remove it. 10. REMOVE FRONT AND REAR GARNISH Using a screwdriver, remove the garnishes. HINT: Tape the screwdriver tip before use. BO–102 BODY – SLIDING ROOF 11. REMOVE ROOF DRIP CHANNEL (a) Remove 2 screws. (b) Pull the channel forwards to remove it. 12. REMOVE WIND DEFLECTOR PANEL (a) Slide the drive cable backwards. (b) Remove 4 screws and the panel. 13. REMOVE CABLE GUIDE CASING ASSEMBLY (a) Slide the drive cable forwards. (b) Remove 11 screws. (c) Apply adhesive tape to protect the body. (d) Pull the cable guide casing assembly forwards to remove it. BO–103 BODY – SLIDING ROOF SLIDING ROOF DISASSEMBLY 1. REMOVE SLIDING ROOF PANEL STOPPER Remove the screw and the stopper. 2. REMOVE SUNSHADE TRIM Pull the trim rearwards to remove it. 3. REMOVE CABLE GUIDE CASING Remove 2 screws and the casing. 4. REMOVE SLIDING ROOF FRONT STOPPER Remove the screw and the stopper. 5. REMOVE DRIVE CABLE (a) Remove 2 screws and the cable guide block. (b) Pull the drive cable from the guide rail. BO–104 BODY – SLIDING ROOF SLIDING ROOF ASSEMBLY 1. INSTALL DRIVE CABLE (a) Insert the drive cable to the drive rail. (b) Install the cable guide block with 2 screws. 2. INSTALL SLIDING ROOF FRONT STOPPER Install the stopper with the screw. 3. INSTALL CABLE GUIDE CASING (a) Install the casing with 2 screws. (b) Use butyl tape to cover the cut position of the weath– erstrip at the connection between the guide casing and the guide rail. 4. INSTALL SUNSHADE TRIM 5. INSTALL SLIDING ROOF PANEL STOPPER Install the stopper with the screw. BO–105 BODY – SLIDING ROOF SLIDING ROOF INSTALLATION 1. INSTALL CABLE GUIDE CASING ASSEMBLY (a) Apply adhesive tape to protect the body. (b) Push the cable guide casing assembly rearwards to remove it. (c) Install 11 screws. 2. INSTALL WIND DEFLECTOR PANEL Install the panel with 4 screws. 3. ADJUST DRIVE RAIL HINT: Adjust the drive rail to a closed and tilted down position. Using a screwdriver, slide the link forwards or rear– wards to align the 2 marks as shown. BO–106 BODY – SLIDING ROOF 4. INSTALL ROOF DRIP CHANNEL (a) Push the channel rearwards to install it. (b) Install 2 screws. 5. INSTALL FRONT AND REAR GARNISH Tap the garnishes to install it. 6. INSTALL SLIDING ROOF GLASS Install the glass and the shims with 6 nuts. 7. INSTALL DRIVE GEAR (a) Remove the screw and cam plate cover. (b) Remove the large screw, washers and shims. (c) Turn the drive shaft by screwdriver to align the hous– ing and gear point mark as shown. (d) Install the cam plate cover with the screw. (e) Apply adhesive to 2 gear side bolts. Part No.08833–00070, THREE BOND 1324 or equivalent (f) Install the drive gear with 3 bolts. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) (g) Connect the connectors. BO–107 BODY – SLIDING ROOF 8. INSTALL SLIDING ROOF CONTROL RELAY (a) Install the relay with the bolt. (6) Connect the connector. 9. INSTALL FRONT SIDE OF ROOF HEADLINING Connect the front side of roof headlining to the front side of housing. 10. INSTALL SLIDING ROOF SWITCH (a) Install the switch with 2 screws, then connect the connectors. (b) Install the cover. 11. INSPECT AND ADJUST SLIDING ROOF (See pages BO–98 to 100) 12. INSTALL SIDE GARNISH Tap the garnishes to install it. 13. INSTALL FOLLOWING PARTS: (a) Front pillar garnish (b) Front assist grip (c) Sunvisors and holders (d) Inner rear view mirror 14. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY BO–108 BODY – INSTRUMENT PANEL INSTRUMENT PANEL COMPONENTS BO–109 BODY – INSTRUMENT PANEL COMPONENTS (Cont’d) BO–110 BODY – INSTRUMENT PANEL HINT: Screw sizes in the illustration on the previous page are indicated using the code below for removal and installation of instrument panel. INSTRUMENT PANEL REMOVAL 1. DISCONNECT BATTERY CABLE FROM NEGATIVE TERMINAL CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE FRONT PILLAR GARNISH (a) Sedan, Wagon: Remove the clips by your hand. BO–111 BODY – INSTRUMENT PANEL (b) Sedan, Wagon: Pull the garnish rearwards to remove it. (e) Coupe: Rear side garnish must ba removed before front piller garnish. 3. REMOVE FRONT DOOR INSIDE SCUFF PLATE Remove the scuff plate by pulling. 4. REMOVE FRONT DOOR OPENING COVER Remove the cover by pulling. 5. REMOVE HOOD LOCK RELEASE LEVER (a) Remove 2 screws. (b) Slide the lever forwards to remove it. BO–112 BODY – INSTRUMENT PANEL 6. REMOVE COWL SIDE TRIM (a) Remove the clip. (b) Remove the trim by pulling. 7. REMOVE STEERING WHEEL (See page SR–5) 8. REMOVE STEERING COLUMN COVER Remove 5 screws and the covers. 9. REMOVE CONSOLE UPPER PANEL Using a screwdriver, remove the panel then discon– nect the connector. HINT: Tape the screwdriver tip before use. 10. REMOVE REAR CONSOLE BOX Remove 2 bolts, 2 screws and the box. 11. REMOVE COIN BOX (a) Press on the sides of the box while pulling the box outwards. (b) Remove the box. BO–113 BODY – INSTRUMENT PANEL 12. REMOVE INSTRUMENT PANEL LOWER PAD (a) Remove 2 screws and the coin box bezel. (b) Remove 4 bolts, the screw and the lower pad. 13. REMOVE COMBINATION SWITCH (a) Disconnect the connectors. (b) Remove 4 screws and the combination switch. 14. REMOVE UNDER COVER NO. 2 Remove the under cover No.2 by pulling. 15. REMOVE INSTRUMENT LOWER PANEL (a) Remove 2 screws. (b) Remove the lower panel by pulling. 16. REMOVE FRONT CONSOLE BOX (a) Remove 2 clips. (b) Remove 2 screws and the box. BO–114 BODY – INSTRUMENT PANEL 17. REMOVE GLOVE COMPARTMENT DOOR Remove 3 nuts and the door. 18. REMOVE GLOVE COMPARTMENT HINT: Tape a screwdriver tip before use. (a) Remove the glove compartment door finish plate inside the instrument panel box. NOTICE: When handling the airbag connector, take care not to damage the airbag wire harness. (b) Pull up and disconnect the airbag connector. (c) Remove 5 screws. (d) Remove the compartment by pulling. 19. REMOVE CENTER CLUSTER FINISH PANEL Using a screwdriver, remove the panel then discon– nect the connectors. HINT: Tape the screwdriver tip before use. 20. REMOVE CLUSTER FINISH PANEL (a) Remove 4 screws. (b) Using a screwdriver remove the panel. HINT: Tape the screwdriver tip before use. (c) Disconnect the connectors. BO–115 BODY – INSTRUMENT PANEL 21. REMOVE REGISTER NO. 1 AND NO. 2 (a) Remove 2 screws and the register No.1. (b) Remove 2 screws and the register No.2. 22. REMOVE RADIO Remove 4 bolts and the radio, then disconnect the connectors. 23. REMOVE COMBINATION METER Remove 4 screws and the meter, then disconnect the connectors. 24. REMOVE HEATER CONTROL (a) Pull of the heater control knobs. (b) Remove 5 screws and hang the heater control. (c) Disconnect the air mix damper control cable. (d) Remove the heater control. BO–116 BODY – INSTRUMENT PANEL 25. REMOVE DUCT HEATER TO REGISTER NO. 2 Remove the clip and the register No.2. 26. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY (a) Remove the LH side installation bolt. (b) Remove 5 bolts and 2 clips. CAUTION: • Do not store the front passenger airbag assembly with the airbag door facing down. • Never disassemble the front passenger airbag as– sembly. 27. REMOVE SIDE DEFROSTER NOZZLE NO. 2 Using a screwdriver, remove the nozzle No.2. HINT: Tape the screwdriver tip before use. 28. REMOVE INSTRUMENT PANEL (a) Disconnect the connectors. (b) Remove the bolt. (c) Remove the connector holder. BO–117 BODY – INSTRUMENT PANEL (d) Disconnect the connectors. (e) Remove the bolt. (f) Remove the connector holder. (g) Disconnect the connector. (h) Remove the bolt. (i) Remove 8 bolts, 2 nuts and the instrument panel. (j) Remove the duct heater to register No.4 and No.5. BO–118 BODY – INSTRUMENT PANEL 29. REMOVE INSTRUMENT PANEL REINFORCEMENT Remove the parts as shown below. INSTRUMENT PANEL DISASSEMBLY 1. REMOVE FOLLOWING PARTS FROM INSTRUMENT PANEL (a) Duct heater to register No.1 (b) Duct heater to register No.3 (c) Defroster nozzle (d) Register No.3 (e) Center bracket (f) Mounting bracket No.1 (g) Safety Pad Sub–Assembly (h) Side Defroster nozzle No.1 (i) Lower finish panel 2. REMOVE LOWER MOUNTING BRACKET NO. 1 Remove 2 bolts and the bracket No.1. 3. REMOVE LOWER MOUNTING BRACKET NO. 2 Remove 2 bolts and the bracket No.2. 4. REMOVE INSTRUMENT PANEL WIRE Remove 5 screws, the clip and the wire. BO–119 BODY – INSTRUMENT PANEL INSTRUMENT PANEL ASSEMBLY ASSEMBLE INSTRUMENT PANEL PARTS BY FOLLOW– ING DISASSEMBLY SEQUENCE IN REVERSE INSTRUMENT PANEL INSTALLATION INSTALL INSTRUMENT PANEL PARTS BY FOLLOWING REMOVAL SEQUENCE IN REVERSE TORQUE FOLLOWING BOLTS: Front passenger airbag assembly (See page RS–34) To instrument panel reinforcement Torque: 20 N–m (210 kgf–cm, 15 ft–lbf) To instrument panel Torque: 8.0 N–m (80 kgf–cm, 69 in.–lbt) NOTICE: The 2 bolts to the instrument panel have been anti–rust treated. When the front passenger airbag as– sembly is removed, always replace the bolts with now ones. BO–120 BODY – SEAT SEAT COMPONENTS BO–121 BODY – SEAT COMPONENTS (Cont’d) BO–122 BODY – SEAT COMPONENTS (Cont’d) BO–123 BODY – SEAT COMPONENTS (Cont’d) BO–124 BODY – SEAT COMPONENTS (Cont’d) BO–125 BODY – SEAT COMPONENTS (Cont’d) BO–126 BODY – SEAT COMPONENTS (Cont’d) BO–127 BODY – SEAT BELT SEAT BELT COMPONENTS BO–128 BODY – SEAT BELT COMPONENTS (Cont’d) BO–129 BODY – SEAT BELT COMPONENTS (Cont’d) BO–130 BODY – SEAT BELT COMPONENTS (Cont’d) BO–131 BODY – SEAT BELT COMPONENTS (Cont’d) BO–132 BODY – SEAT BELT COMPONENTS (Cont’d) BO–133 BODY – SEAT BELT SEAT BELT INSPECTION Emergency Locking Retractor (ELR) and Automatic Locking Retractor (ALR) type 1. RUNNING TEST (INN SAFE AREA) for all seat: (a) Fasten the front seat belts. (b) Drive the car at 10 mph (16 km/h) and make a very hard stop. (c) Check that the belt is locked and cannot be extended at this time. HINT: Conduct this test in a safe area. If the belt does not lock, remove the belt mechanism assembly and conduct the following static check. Also, whenever installing a new belt assembly, verify the proper oper– ation before installation. 2. STATIC TEST for driver’s seat (ELR): (a) Verify that the belt locks when pulled out quickly. (b) Remove the locking retractor assembly. (c) Tilt the retractor slowly. (d) Verify that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out over 45 degrees of tilt. If a problem is found, replace the assembly. except for driver’s seat (ALR/ ELR): (a) Verify that the belt locks when pulled out quickly. (b) Remove the locking retractor assembly. (c) Pull out the whole belt and measure the length of the whole belt. Then retract the belt slightly and pull it out again. (d) Verify that the belt cannot be extended further. If a problem is found, replace the assembly. (e) Retract the whole belt, then pull out the belt until 200 mm (7.87 in.) of belt remains retracted. (f) Tilt the retractor slowly. (g) Verify that the belt can be pulled out at a tilt of 15 degrees or less, and cannot be pulled out at over 45 degrees of tilt. If a problem is found, replace the assembly. BO–134 BODY – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS TORQUE SPECIFICATIONS Part tightened FRONT BUMPER Front bumper arm x Body Front bumper reinforcement x Front bumper arm Reinforcement extension x Body REAR BUMPER Rear bumper arm x Body Rear bumper reinforcement x Rear bumper arm Rear bumper cover x Body HOOD. Hood hinge x Hood Hood Lock x Body FRONT DOOR AND REAR DOOR Door lock x Door panel Window regulator x Door inside panel frame Window regulator x Door panel BACK DOOR Back door hinge x Body Back door hinge x Back door Back door lock x Back door Back door damper stay x Body Back door damper stay x Back door LUGGAGE COMPARTMENT Luggage compartment door hinge x Luggage compartment door WIPER AND WASHER Wiper arm x Wiper link Wiper arm x Wiper pivot Wiper pivot x Back door SLIDING ROOF Drive gear x Body SEAT Front Seat Seat truck x Body Rear Seat Seat back x Body Seat back x Seat hinge Seat hinge x Body Second Seat Rear side seatback x Body Seat back x Seatback hinge Seatback hinge x Body Seat cushion hinge x Body Third Seat Seatback link x Bracket BO–135 BODY Bracket x Body SEAT BELT Front Seat Belt Shoulder anchor x Adjustable anchor Outer belt anchor x Body ELR x Body Adjustable anchor x Body Inner belt x Seat Rear Seat Belt Shoulder anchor x Body Outer belt anchor x Body ELR x Body Inner belt x Body Center belt x Body (CANADA) CRS, tether anchor x Body Second Seat Belt Shoulder anchor x Body Outer belt anchor x Body ELR x Body Inner belt x Body Center belt x Body (CANADA) CRS, tether anchor x Body Third Seat Belt Shoulder anchor x Body Outer belt anchor x Body ELR x Body Inner belt x Body – SERVICE SPECIFICATIONS BR–1 BRAKE SYSTEM – BRAKE SYSTEM BR–2 BRAKE SYSTEM – GENERAL DESCRIPTION GENERAL DESCRIPTION 1. Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts of the same part number or equivalent. 2. It is very important to keep parts and the area clean when repairing the brake system. 3. If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section. DESCRIPTION The service brakes consist of a foot brake which changes rotational energy to thermal energy to stop the vehicle while it is being driven and a parking brake to keep the vehicle from moving while it is parked. BR–3 BRAKE SYSTEM – OPERATION OPERATION FOOT BRAKE when the brake pedal is depressed, a vacuum builds up in the booster which amplifies the pedal force, pressing on the piston in the master cylinder. The piston movement raises the hydraulic pressure in the cylinder. This hydraulic pressure is then applied to each front caliper and rear wheel cylinder (or rear caliper), and acts to press the front brake pads and rear brake shoes (or rear brake pads) against the rotating drums (or discs). The resulting friction converts the rotational energy to thermal energy, stopping the vehicle. BR–4 BRAKE SYSTEM – OPERATION PARKING BRAKE Rear Drum Brake: When the parking brake lever is pulled, the parking brake shoe lever is pulled via the parking brake wire. This causes the adjuster to push the front shoe, which expands and is pressed against the brake drum. If the parking brake lever continues to be pulled, the contact point of the parking brake shoe lever and adjuster then becomes the fulcrum so that the parking brake shoe lever causes the rear shoe to expand. This results in the brake drum being locked by the front shoe and rear shoe. PARKING BRAKE Rear Disc Brake: When the parking brake lever is pulled or pedal is depressed, the parking brake shoe lever is pulled via the parking brake wire. This causes the shoe strut to push the front shoe, which expands and is pressed against the disc. If the parking brake lever or pedal continues to be pulled or depressed, the contact point of the parking brake shoe lever and shoe strut then becomes the fulcrum so that the parking brake shoe lever causes the rear shoe to expand. This results in the disc being locked by the front shoe and rear shoe. BR–5 BRAKE SYSTEM – PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) 09023–00100 Union Nut Wrench 10 mm 09703–30010 Brake Shoe Return Spring Tool 09709–29017 LSPV Gauge Set 09718–00010 Shoe Hold Down Spring Driver 09737–00010 Brake Booster Push Rod Gauge 09751–36011 Brake Tube Union Nut 10 x 12 mm Wrench 09843–18020 Diagnosis Check Wire 09990–00150 A6S Actuator Checker and Sub–harness TMC made vehicle (NIPPONDENSO ABS) 09990–00163 ABS Actuator Checker Sheet ’A’ TMC made vehicle (NIPPONDENSO ABS) 09990–00200 ABS Actuator Checker Sub–harness “C” TMC made vehicle (NIPPONDENSO ABS) 09990–00210 ABS Actuator Checker Sub–harness “E” TMC made vehicle (NIPPONDENSO ABS) BR–6 BRAKE SYSTEM – PREPARATION RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set 09905–00013 Snap Ring Pliers EQUIPMENT Torque wrench Micrometer Brake disc Dial indicator Brake disc Vernier calipers Brake drum and disc LUBRICANT Item Brake fluid Capacity Classification SAE J 1703 or FMVSS No. 116 DOT3 Low pedal or spongy pedal Brake drag Brake pull Hard pedal but brake inefficient Noise from brakes Part Name (Trouble) Hold–down spring (Damaged) Anti–squeal shim (Damaged) Pad or lining (Hardened) Pad or lining (Dirty) Rotor (Scored) Sliding pin (Worn) Installation bolt (Loose) Pad support plate (Loose) Booster system (Vacuum leaks) Piston (Frozen) Pad or lining (oily) Piston (Stuck) Pad or lining (Cracked or distorted) Anchor or return spring (Faulty) Booster push rod (Out of adjustment) BR–37 BR–21,29,44 BR–21,29,37,44 BR–21,29,37,44 BR–21,29,44 BR21, 29, 44 BR–21,29,37,44 BR–21,29,44 BR–9 BR–21,29,37,44 BR–21,29,37,44 BR–21,29,37,44 BR–21,29,37,44 BR–37 BR–17 BR–10,11 Parking brake (Lever or pedal travel out of adjustment) – Parking brake wire (Sticking) BR–37,44 BR–12 BR–8 BR–21,29,44 BR–21,29,37,44 Rear brake (Shoe clearance out of adjustment) Master cylinder (Faulty) Brake pedal (Freeplay minimal) Piston seal (Worn or damaged) See page Brake pad or lining (Worn) Brake system (Air in) Brake system (Fluid leaks) BRAKE SYSTEM TROUBLESHOOTING BR–7 TROUBLESHOOTING !M19–0F Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. BR–8 BRAKE SYSTEM – CHECK AND ADJUSTMENT CHECK AND ADJUSTMENT BRAKE PEDAL CHECK AND ADJUSTMENT 1. CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height from asphalt sheet: 147.5–157.5 mm (5.81–6.20 fn.) If the pedal height is incorrect, adjust it. 2. IF NECESSARY, ADJUST PEDAL HEIGHT (a) Disconnect the connector from the stop light switch. (b) Loosen the stop light switch lock nut and remove the stop light switch. (c) Loosen the push rod lock nut. (d) Adjust the pedal height by turning the pedal push rod. (e) Tighten the push rod lock nut. Torque: 25 N–m (260 kgf–cm, 19 ft–lbf) (f) Install the stop light switch and turn it until it lightly contacts the pedal stopper. (g) Turn the stop light switch back one turn. (h) Check the clearance (A) between stop light switch and pedal. Clearance: 0.5–2.4 mm (0.02–0.09 in.) (i) Tighten the stop light switch lock nut. (j) Connect the connector to the stop light switch. (k) Check that the stop lights come on when the brake pedal is depressed, and go off when the brake pedal is released. (l) After adjusting the pedal height, check that pedal freeplay. HINT: If clearance (A) between the stop light switch and the brake pedal stopper has been adjusted cor– rectly, the pedal freeplay will meet the specifications. 3. CHECK THAT PEDAL FREEPLAY IS CORRECT (a) Stop the engine and depress the brake pedal several times until there is no more vacuum left in the boost– er. (b) Push in the pedal by hand until the beginning of the resistance is felt, then measure the distance. Pedal freeplay: 1–6 mm (0.04–0.24 in.) HINT: The freeplay to the 1st point of resistance is due to the play between the clevis and pin. It is 1–3 mm (0.04–0.12 in.) on the pedal. If incorrect, check the stop light switch clearance. And if the clearance is OK, then troubleshoot the brake system. BR–9 BRAKE SYSTEM – CHECK AND ADJUSTMENT 4. CHECK THAT PEDAL RESERVE DISTANCE IS COR– RECT Release the parking brake. With the engine running, depress the pedal and meas– ure the pedal reserve distance. Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 70 mm (2.76 in.) If the reserve distance is incorrect, troubleshoot the brake system. BRAKE BOOSTER OPERATIONAL TEST 1. OPERATING CHECK (a) Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. (b) Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal. 2. AIR TIGHTNESS CHECK (a) Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. If the pedal goes down farthest the 1 st time, but gradually rises after the 2nd or 3rd time, the booster is air tight. (b) Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. If there is no change in the pedal reverse travel after holding the pedal for 30 seconds, the booster is air tight. BRAKE SYSTEM BLEEDING HINT: If any work is done on the brake system or if air in the brake lines is suspected, bleed the system of air. NOTICE: Do not let brake fluid remain on a painted sur– face. Wash it off immediately. 1. FILL BRAKE RESERVOIR WITH BRAKE FLUID Fluid: SAE J1703 or FMVSS No. 116 DOT3 2. BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air from the master cylinder. (a) Disconnect the brake lines from the master cylinder. (b) Slowly depress the brake pedal and hold it. BR–10 BRAKE SYSTEM – CHECK AND ADJUSTMENT (c) Block off the outer holes with your fingers, and re– lease the brake pedal. (d) Repeat (b) and (c) 3 or 4 times. 3. BLEED BRAKE LINE (a) Connect the vinyl tube to the brake caliper. (b) Depress the brake pedal several times, then loosen the bleeder plug with the pedal held down. (c) At the point when fluid stops coming out, tighten the bleeder plug, then release the brake pedal. (d) Repeat (b) and (c) until all the air in the fluid has been bled out. (e) Repeat the above procedure to bleed the air out of the brake line for each wheel. 4. CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No.116 DOT3 LEVER TYPE PARKING BRAKE CHECK AND ADJUSTMENT 1. CHECK THAT PARKING BRAKE LEVER TRAVEL IS CORRECT Pull the parking brake lever all the way up, and count the number of clicks. Parking brake lever travel at 196 N (20 kgf, 44 lbf): 5–8 clicks If incorrect, adjust the parking brake. 2. IF NECESSARY, ADJUST PARKING BRAKE LEVER TRAVEL HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. For shoe clearance adjustment, see step 9 on page BR–43 or step 8 on page BR–58. (a) Remove the rear console box. (b) Loosen the lock nut and turn the adjusting nut until the lever travel is correct. BR–11 BRAKE SYSTEM – CHECK AND ADJUSTMENT (c) Tighten the lock nut. Torque: 5.4 N–m (55 kgf–cm. 48 in.¿lbf) (d) Install the rear console box. PEDAL TYPE PARKING BRAKE CHECK AND ADJUSTMENT 1. CHECK THAT PARKING BRAKE PEDAL TRAVEL IS CORRECT Slowly depress the parking brake pedal all the way, and count the number of clicks. Parking brake pedal travel at 294 N (30 kgf,66 lbf): 3–6 clicks If incorrect, adjust the parking brake. 2. IF NECESSARY, ADJUST PARKING BRAKE PEDAL TRAVEL HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. For shoe clearance adjustment, see step 8 on page BR –58. (a) Remove the hole cover. (b) Loosen the lock nut and turn the adjusting nut until the lever travel is correct. (c) Tighten the lock nut. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) (d) Install the hole cover. BR–12 BRAKE SYSTEM – MASTER CYLINDER MASTER CYLINDER MASTER CYLINDER REMOVAL 1. DISCONNECT LEVEL WARNING SWITCH CONNEC – TOR 2. TAKE OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted sur– face. Wash it off immediately. 3. DISCONNECT BRAKE LINES Using SST, disconnect the brake lines from the master cylinder. SST 09023–00100 4. REMOVE MASTER CYLINDER Remove the mounting nuts and pull out the master cylinder and gasket. BR–13 BRAKE SYSTEM – MASTER CYLINDER COMPONENTS BR–14 BRAKE SYSTEM – MASTER CYLINDER MASTER CYLINDER DISASSEMBLY 1. REMOVE MASTER CYLINDER BOOT Using a screwdriver, remove the master cylinder boot. 2. REMOVE RESERVOIR (a) Remove the set screw and pull out the reservoir. (b) Remove the cap and strainer from the reservoir. 3. REMOVE 2 GROMMETS 4. PLACE CYLINDER IN VISE 5. REMOVE PISTON STOPPER BOLT Using a screwdriver, push the pistons in all the way and remove the piston stopper bolt and gasket. HINT: Tape the screwdriver tip before use. 6. REMOVE 2 PISTONS AND SPRINGS (a) Push in the piston with a screwdriver and remove the snap ring with snap ring pliers. (b) Remove the No.1 piston and spring by hand, pulling straight out, not at an angle. NOTICE: If pulled out at an angle, there is a possibility that the cylinder bore could be damaged. (c) Place a rag and 2 wooden blocks on the work table and lightly tap the cylinder flange against the blocks until the piston drops out of the cylinder. HINT: Make sure the distance (A) from the rag to the top of the blocks is at least 100 mm (3.94 in.). BR–15 BRAKE SYSTEM – MASTER CYLINDER MASTER CYLINDER INSPECTION HINT: Clean the disassembled parts with compressed air. 1. INSPECT CYLINDER BORE FOR RUST OR SCORING 2. INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder. MASTER CYLINDER ASSEMBLY 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO RUBBER PARTS INDICATED BY ARROWS 2. INSTALL 2 SPRINGS AND PISTONS NOTICE: Be careful not to damage the rubber lips on the pistons. (a) Install the 2 springs and pistons straight in, not at an angle. NOTICE: If install at an angle, there is a possibility of damaging the cylinder bore. (b) Push in the piston with a screwdriver and install the snap ring with snap ring pliers. HINT: Tape the screwdriver tip before use. 3. INSTALL PISTON STOPPER BOLT Using a screwdriver, push the piston in all the way and install the piston stopper bolt over a new gasket. Torque the bolt. Torque: 10 N .m (100 kgf–cm, 7 ft–lbf) BR–16 BRAKE SYSTEM – MASTER CYLINDER 4. INSTALL 2 GROMMETS 5. INSTALL RESERVOIR (a) Install the strainer and cap to the reservoir. (b) Push the reservoir onto the cylinder. (c) Install the set screw while pushing on the reservoir. Torque: 1.7 N–m (17.5 kgf–cm, 15.2 in.–lbf) 6. INSTALL MASTER CYLINDER BOOT Facing the UP mark on the master cylinder boot up– wards, install the cylinder boot to the master cylinder. MASTER CYLINDER INSTALLATION 1. ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD BEFORE INSTALLING MASTER CYLINDER (See page BR–19) 2. INSTALL MASTER CYLINDER Install the master cylinder and a new gasket on the brake booster with 3 nuts. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) BR–17 BRAKE SYSTEM – MASTER CYLINDER 3. CONNECT 2 BRAKE LINES Using SST, connect the brake lines to the master cylinder_ Torque the union nuts. SST 09023–00100 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 4. CONNECT LEVEL WARNING SWITCH CONNECTOR 5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 6. CHECK FOR LEAKS 7. CHECK AND ADJUST BRAKE PEDAL (See page BR–8) BR–18 BRAKE SYSTEM – BRAKE BOOSTER BRAKE BOOSTER BRAKE BOOSTER REMOVAL 1. REMOVE MASTER CYLINDER (See page BR–12) 2. PUSH DOWN CHARCOAL CANISTER Loosen the clamp screw and push the charcoal canis– ter down slightly. BR–19 BRAKE SYSTEM – BRAKE BOOSTER 3. DISCONNECT VACUUM HOSE FROM BRAKE BOO– STER 4. REMOVE PEDAL RETURN SPRING 5. REMOVE CLIP AND CLEVIS PIN 6. REMOVE BRAKE BOOSTER, GASKET AND CLEVIS (a) Remove the 4 nuts and clevis. (b) Pull out the brake booster and gasket. BRAKE BOOSTER INSTALLATION 1. INSTALL BRAKE BOOSTER (a) Install the booster and a new gasket. (b) Install the clevis to the operating rod. (c) Install and torque the booster installation nuts. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) (d) Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin. (e) Install the pedal return spring. 2. ADJUST LENGTH OF BOOSTER PUSH ROD (a) Install the gasket on the master cylinder. (b) Set the SST on the gasket, and lower the pin until its tip slightly touches the piston. (c) Turn the SST upside down, and set it on the booster. (d) Measure the clearance between the booster push rod and pin head (SST). Clearance: 0 mm (0 in.) (e) Adjust the booster push rod length until the push rod slightly touches the pin head. 3. INSTALL CHARCOAL CANISTER TO ORIGINAL PO– SITION 4. INSTALL MASTER CYLINDER 5. CONNECT VACUUM HOSE TO BRAKE BOOSTER 6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 7. CHECK FOR LEAKS BR–20 BRAKE SYSTEM – BRAKE BOOSTER 8. CHECK AND ADJUST BRAKE PEDAL (See page BR–8) Check and adjust the brake pedal, then tighten the clevis lock nut. Torque: 25 N–m (260 kgf–cm, 19 ft–lbf) 9. PERFORM OPERATIONAL CHECK (See page BR–9) BR–21 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) FRONT BRAKE (Single–Piston Type) COMPONENTS BRAKE PADS REPLACEMENT 1. REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with hub nuts. BR–22 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspec– tion hole and replace the pads if it is not within the specification. Minimum thickness: 1.0 mm (0.039 in.) 3. LIFT UP CALIPER (a) Hold the sliding pin on the bottom and loosen the installation bolt. (b) Remove the installation bolt. (c) Lift up the caliper and suspend the caliper with string. HINT: Do not disconnect the flexible hose from the caliper. 4. REMOVE FOLLOWING PARTS: (a) 2 anti–squeal springs (b) 2 brake pads (c) 4 anti–squeal shims (d) 1 MZ–FE engine: Pad wear indicator (e) 4 pad support plates 5. CHECK DISC THICKNESS AND RUNOUT (See page BR–26) BR–23 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 6. INSTALL PAD SUPPORT PLATES Install the 4 pad support plates. 7. INSTALL NEW PADS (a) 1 MZ–FE engine: Install a pad wear indicator plate on the inside pad. (b) Apply disc brake grease to both sides of the inner anti –squeal shim. (c) Install the 2 anti–squeal shims on each pad. (d) install inside pad with the pad wear indicator plate facing upward. (e) Install outside pad. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. (f) Install the 2 anti–squeal springs. 8. INSTALL CALIPER (a) Draw out a small amount of brake fluid from the reservoir. (b) Press in the piston with water pump pliers or similar implement. HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. BR–24 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) (c) Install the caliper. (d) Hold the sliding pin and torque the installation bolt. Torque: 34 N–m (350 kgf–cm, 25 ft–lbf) 9. INSTALL FRONT WHEEL 10. CHECK THAT FLUID LEVEL IS AT MAX LINE CALIPER REMOVAL 1. DISCONNECT FLEXIBLE HOSE (a) Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. (b) Use a container to catch the brake fluid as it drains out. 2. REMOVE CALIPER (a) Hold the sliding pin and loosen the 2 installation bolts. (b) Remove the 2 installation bolts. (c) Remove the caliper from the torque plate. 3. REMOVE 2 BRAKE PADS Remove the inside and outside pads. CALIPER DISASSEMBLY 1. REMOVE CYLINDER BOOT SET RING AND CYLIN– DER BOOT Using a screwdriver, remove the cylinder boot set ring and cylinder boot from the caliper. BR–25 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 2. REMOVE PISTON (a) Place a piece of cloth or similar article between the piston and the caliper. (b) Use compressed air to remove the piston from the cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed sir. 3. REMOVE PISTON SEAL Using a screwdriver, remove the piston seal from the cylinder. 4. REMOVE SLIDING PINS AND DUST BOOTS (a) Remove the 2 sliding pins from the torque plate. (b) Using a screwdriver and hammer, tap out the 2 dust boots. BR–26 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) FRONT BRAKE COMPONENTS INSPECTION AND REPAIR 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 5S–FE engine 12.0 mm (0.472 In.) 1 MZ–FE engine 11.0 mm (0.433 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad’s thickness is at the mini– mum thickness or less, or if the pad has excessively uneven wear. 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 in.) Minimum thickness: 26.0 mm (1.024 in.) Replace the disc if the disc’s thickness is at the mini– mum thickness or less. Replace the disc or grind it on a lathe if it is badly scored or worn unevenly. 3. MEASURE DISC RUNOUT Measure disc runout 10 mm (0.39 in.) from the outer edge of the disc. Maximum disc runout: 0.05 mm (0.0020 in.) If runout is greater than maximum, attempt to adjust to below this maximum figure. HINT: Before measuring the runout, confirm that the front bearing play is within specification. 4. IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the torque plate from the knuckle. (b) Remove the hub nuts and the disc. Reinstall the disc 1/5 of a turn round from its original position on the hub. Install and torque the hub nuts. Torque: 103 N–m (1,050 kgf–cm, 76 ft–lbf) Remeasure the disc runout. Make a note of the runout and the disc’s position on the hub. BR–27 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) (c) Repeat (b) until the disc has been installed on the 3 remaining hub positions. (d) If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020in.), install the disc in that position. (e) If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3. (f) Install the torque plate and torque the mounting bolts. Torque: 107 N–m (1,090 kgf–cm, 79 ft–lbf) CALIPER ASSEMBLY 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO PARTS INDICATED WITH ARROWS 2. INSTALL DUST BOOTS AND SLIDING PINS (a) Using a 19 mm socket wrench and hammer, tap in 2 new dust boots into the torque plate. (b) Confirm that the metal plate portion of the dust boot fits snugly in the torque plate. (c). Insert 2 sliding pins into the torque plate. NOTICE: Insert the sliding pin with sliding bushing into the bottom side. 3. INSTALL PISTON SEAL AND PISTON IN CYLINDER BR–28 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 4. INSTALL CYLINDER BOOT AND CYLINDER BOOT SET RING CALIPER INSTALLATION 1. INSTALL 2 BRAKE PADS Install the inside and outside pads. 2. INSTALL CALIPER (a) Temporarily install the caliper on the torque plate with the 2 installation bolts. (b) Hold the sliding pin and torque the installation bolt. Torque: 34 N–m (350 kgf–cm, 25 ft–lbf) 3. CONNECT FLEXIBLE HOSE Install the flexible hose on the caliper with 2 new gaskets. Torque: 29 N–m (300 kgf–cm, 21 ft–lbf) HINT: Install the flexible hose lock securely in the lock hole in the caliper. 4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 5. CHECK FOR LEAKS BR–29 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) FRONT BRAKE (2–Piston Type) COMPONENTS BRAKE PADS REPLACEMENT 1. REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with the hub nuts. BR–30 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspec– tion hole and replace the pads if it is not within the specification. Minimum thickness: 1.0 mm (0.039 in.) 3. LIFT UP CALIPER (a) Hold the sliding pin on the bottom and loosen the installation bolt. (b) Remove the installation bolt. (c) Lift up and suspend the caliper. HINT: Do not disconnect the flexible hose from the brake caliper. 4. REMOVE FOLLOWING PARTS: (a) 2 anti–squeal springs (b) 2 brake pads (c) 4 anti–squeal shims (d) 4 pad support plates (e) Pad wear indicator 5. CHECK DISC THICKNESS AND RUNOUT (See page BR–33) 6. INSTALL PAD SUPPORT PLATES Install the 4 pad support plates. BR–31 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 7. INSTALL NEW PADS (a) Install the pad wear indicator plate on the pad. (b) Apply disc brake grease to both sides of the inner anti–squeal shim. (c) Install the 2 anti–squeal shims on each pad. (d) Install the inner pad with the pad wear indicator plates facing upward. (e) Install the outer pad. NOTICE: There should be no oil or grease adhering to the friction surface’s of the pads or the disc. (f) Install the 2 anti–squeal springs. 8. INSTALL CALIPER (a) Draw out a small amount of brake fluid from the reservoir. (b) Press in the piston with a hammer handle or similar implement. HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. (c) Install the caliper. (d) Hold the sliding pin and torque the installation bolt. Torque: 34 N .m (350 kgf–cm, 25 ft–lbf) 9. INSTALL FRONT WHEEL 10. CHECK THAT FLUID LEVEL IS AT MAX LINE CALIPER REMOVAL 1. DISCONNECT FLEXIBLE HOSE (a) Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. (b) Use a container to catch the brake fluid as it drains out. BR–32 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. REMOVE CALIPER (a) Hold the sliding pin and loosen the 2 installation bolts. (b) Remove the 2 installation bolts. (c) Remove the caliper from the torque plate. 3. REMOVE FOLLOWING PARTS: (a) 2 anti–squeal springs (b) 2 brake pads with anti–squeal shims (c) 4 pad support plates CALIPER DISASSEMBLY 1. REMOVE CYLINDER BOOT SET RINGS AND CYLIN– DER BOOTS Using a screwdriver, remove the 2 cylinder boot set rings and cylinder boots from the caliper. 2. REMOVE PISTONS (a) Place a piece of cloth or similar article between the piston and caliper. (b) Use compressed air to remove the pistons from the cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed air. 3. REMOVE PISTON SEALS Using a screwdriver, remove the 2 piston seals from the cylinder. BR–33 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 4. REMOVE SLIDING PINS AND DUST BOOTS (a) Remove the 2 sliding pins from the torque plate. (b) Using a screwdriver and hammer, tap out the 2 dust boots. FRONT BRAKE COMPONENTS INSPECTION AND REPAIR 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 11.0 mm (0.433 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad’s thickness is at the mini– mum thickness or less, or if the pad has excessively uneven wear. 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 28 mm (1.102 in.) Minimum thickness: 26 mm (1.024 in.) Replace the disc if the disc’s thickness is at the mini– mum thickness or less. Replace the disc or grind it on a lathe if it is badly scored or worn unevenly. 3. MEASURE DISC RUNOUT Measure disc runout 10 mm (0.39 in.) from the outer edge of the disc. Maximum disc runout: 0.05 mm (0.0020 in.) If runout is greater than maximum, attempt to adjust to below this maximum figure. BR–34 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) HINT: Before measuring the runout, confirm that the front bearing play is within specification. 4. IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the torque plate from the knuckle. (b) Remove the hub nuts and the disc. Reinstall the disc 1/5 of a turn round from its original position on the hub. Install and torque the hub nuts. Torque: 103 N–m (1,050¿¿f¿cm, 76 ft–lbf) Remeasure the disc runout. Make a note of the runout and disc’s position on the hub. (c) Repeat (b) until the disc has been installed on the 3 remaining hub positions. (d) If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020 in.), install the disc in that position. (e) If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3. (f) Install the torque plate and torque the mounting bolts. Torque: 107 N–m (1,090 kgf–cm, 79 ft–lbf) CALIPER ASSEMBLY 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO PARTS INDICATED WITH ARROWS BR–35 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. INSTALL DUST BOOTS AND SLIDING PINS (a) Using a 19 mm socket and a hammer, tap in 2 new dust boots into the torque plate. (b) Confirm that the metal plate portion of the dust boot fits snugly in the torque plate. (c) Insert 2 sliding pins into the torque plate. NOTICE: Insert the sliding pin with sliding bushing into the bottom side 3. INSTALL PISTON SEALS AND PISTONS IN CYLIN – DER 4. INSTALL CYLINDER BOOTS AND CYLINDER BOOT SET RINGS CALIPER INSTALLATION 1. INSTALL FOLLOWING PARTS: (a) 4 pad support plates (b) 2 brake pads with anti–squeal shims (c) 2 anti–squeal springs BR–36 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. INSTALL CALIPER (a) Temporarily install the caliper on the torque plate with the 2 installation bolts. (b) Hold the sliding pin and torque the installation bolt. Torque: 34 N–m (350 kgf–cm, 26 ft–lbf) 3. CONNECT FLEXIBLE HOSE Install the flexible hose on the brake caliper with 2 new gaskets. Torque: 29 N–m (300 kgf–cm, 21 ft–lbf) HINT: Insert the flexible hose lock securely in the lock hole in the brake caliper. 4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 5. CHECK FOR LEAKS BR–37 BRAKE SYSTEM – REAR BRAKE(Drum Brake) REAR BRAKE (Drum Brake) COMPONENTS REAR DRUM BRAKE REMOVAL 1. INSPECT SHOE LINING THICKNESS Remove the inspection hole plug, and check the shoe lining thickness through the hole. If less than minimum, replace the shoes. Minimum thickness: 1.0 mm (0.039 in.) 2. REMOVE REAR WHEEL 3. REMOVE BRAKE DRUM HINT: If the brake drum cannot be removed easily, perform the following steps. (a) Insert a bent wire or an equivalent through the hole in the brake drum, and hold the automatic adjusting lever away from the adjuster. (b) Using a screwdriver, reduce the brake shoe adjust– ment by turning the adjuster. BR–38 BRAKE SYSTEM – REAR BRAKE(Drum Brake) 4. REMOVE FRONT SHOE (a) Using SST, disconnect the return spring. SST 09703–30010 (b) Using SST, remove the shoe hold–down spring, cups and pin. SST 09718–00010 (c) Disconnect the anchor spring from the front shoe and remove the front shoe. (d) Remove the anchor spring from the rear shoe. 5. REMOVE REAR SHOE (a) Using SST, remove the shoe hold–down spring, cups and pin. SST 09718–00010 (b) Using a screwdriver, disconnect the parking brake cable from the anchor plate. (c) Using pliers, disconnect the parking brake cable from the lever and remove the rear shoe together with the adjuster. 6. REMOVE ADJUSTER FROM REAR SHOE (a) Remove the adjusting lever spring. (b) Remove the adjuster together with the return spring. 7. DISCONNECT BRAKE LINE FROM WHEEL CYLIN– DER Using SST, disconnect the brake line. Use a container to catch the brake fluid. SST 09751–36011 BR–39 BRAKE SYSTEM – REAR BRAKE(Drum Brake) 8. REMOVE WHEEL CYLINDER Remove the 2 bolts and the wheel cylinder. 9. IF NECESSARY, DISASSEMBLE WHEEL CYLINDER Remove the following parts from the wheel cylinder. • 2 boots • 2 pistons • 2 piston cups • Spring REAR DRUM BRAKE COMPONENTS INSPECTION AND REPAIR 1. INSPECT DISASSEMBLED PARTS Inspect the disassembled parts for wear, rust or damage. 2. MEASURE BRAKE SHOE LINING THICKNESS Standard thickness: 5.0 mm (0.197 in.) Minimum thickness: 1.0 mm (0.039 in.) If the shoe lining is less than minimum or shows signs of uneven wear, replace the brake shoes. HINT: If any of the brake shoes have to be replaced, replace all of the rear shoes in order to maintain even braking. 3. MEASURE BRAKE DRUM INSIDE DIAMETER Standard inside diameter: 228.6 mm (9.000 in.) Maximum inside diameter: 230.6 mm (9.079 in.) If the drum is scored or worn, the brake drum may be lathed to the maximum inside diameter. BR–40 • BRAKE SYSTEM – REAR BRAKE(Drum Brake) 4. INSPECT REAR BRAKE LINING AND DRUM FOR PROPER CONTACT If the contact between the brake lining and drum is improper, repair the lining with a brake shoe grinder, or replace the brake shoe assembly. REAR DRUM BRAKE INSTALLATION HINT: Assemble the parts in the correct direction as shown. 1. ASSEMBLE WHEEL CYLINDER (a) Apply lithium soap base glycol grease to the cups and pistons as shown. (b) Assemble the wheel cylinder. HINT: Install in proper direction only. • Spring • 2 cups • 2 pistons • 2 boots 2. INSTALL WHEEL CYLINDER Install the wheel cylinder on the backing plate with the 2 bolts. Torque: 10 N–m (100 kgf–cm, 7 ft–lbf) BR–41 BRAKE SYSTEM – REAR BRAKE(Drum Brake) 3. CONNECT BRAKE LINE TO WHEEL CYLINDER Using SST, connect the brake line. SST 09751–36011 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 4. APPLY HIGH TEMPERATURE GREASE TO BACK – ING PLATE AND ADJUSTER (a) Apply high temperature grease to the brake shoe contact surfaces. (b) Apply high temperature grease to the adjuster bolt threads and ends. 5. INSTALL ADJUSTER ONTO REAR SHOE Set the adjuster and return spring and install the adjusting lever spring. 6. INSTALL REAR SHOE (a) Using pliers, connect the parking brake cable to the lever. (b) Pass the parking brake cable through the notch in the anchor plate. (c) Set the rear shoe in place with the end of the shoe inserted in the wheel cylinder and the other end in the anchor plate. BR–42 BRAKE SYSTEM – REAR BRAKE(Drum Brake) (d) Using SST, install the shoe hold–down spring, cups and pin. SST 09718–00010 NOTICE: Do not allow oil or grease to get on the rubbing face. 7. INSTALL FRONT SHOE (a) Install the anchor spring between the front and rear shoes. (b) Set the front shoe in place with the end of the shoe inserted in the wheel cylinder and the adjuster in place. (c) Using SST, install the shoe hold–down spring, cups and pin. SST 09 718–00010 NOTICE: Do not allow oil or grease to get on the rubbing face. (d) Using SST, connect the return spring. SST 09703–30010 8. CHECK OPERATION OF AUTOMATIC ADJUSTING MECHANISM (a) Move the parking brake lever of the rear shoe back and forth. Check that the adjuster turns. If the adjuster does not turn, check for incorrect installation of the rear brakes. (b) Adjust the adjuster length to the shortest possible amount. BR–43 BRAKE SYSTEM – REAR BRAKE(Drum Brake) (c) Align the adjusting hole on the brake drum and largest hole on the axle carrier, install the brake drum. (d) Pull the parking brake lever all the way up until a clicking sound can no longer be heard. 9. CHECK CLEARANCE BETWEEN BRAKE SHOES AND DRUM (a) Remove the brake drum. (b) Measure the brake drum inside diameter and diameter of the brake shoes. Check that the difference between the diameters is the correct shoe clearance. Shoe clearance: 0.6 mm (0.024 in.) If incorrect, check the parking brake system. 10. INSTALL BRAKE DRUM 11. INSTALL REAR WHEEL 12. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 13. CHECK FOR LEAKS BR–44 BRAKE SYSTEM – REAR BRAKE(Disc Brake) REAR BRAKE (Disc Brake) COMPONENTS BR–45 BRAKE SYSTEM – REAR BRAKE(Disc Brake) BRAKE PADS REPLACEMENT 1. REMOVE REAR WHEEL Remove the wheel and temporarily fasten the disc with the hub nuts. 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspec– tion hole and replace pads if not within specification. Minimum thickness: 1.0 mm (0.039 in.) 3. LIFT UP CALIPER (a) Remove the flexible hose bracket. (b) Remove the installation bolt from the torque plate. (c) Lift up the caliper and suspend the caliper with string. HINT: Do not disconnect the flexible hose from the caliper. BR–46 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 4. REMOVE FOLLOWING PARTS: (a) 2 brake pads (b) 4 anti–squeal shims (c) 4 pad support plates 5. CHECK DISC THICKNESS AND RUNOUT (See page BR–50) 6. INSTALL PAD SUPPORT PLATES Install the 4 pad support plates. 7. INSTALL NEW PADS (a) Apply disc brake grease to both side of the inner anti –squeal shims. (b) Install the 2 anti–squeal shims on each pad. (c) Install 2 pads with the pad wear indicator plates facing up ward. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. 6. INSTALL CALIPER (a) Draw out a small amount of brake fluid from the reservoir. (b) Press in the piston with water pump pliers or similar implement. HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. BR–47 BRAKE SYSTEM – REAR BRAKE(Disc Brake) (c) Install the caliper and torque the installation bolt. Torque: 20 N–m (200 kgf–cm, 14 ft–lbf) (d) Install the flexible hose bracket. Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) 9. INSTALL REAR WHEEL 14. CHECK THAT FLUID LEVEL IS AT MAX LINE CALIPER REMOVAL 1. DISCONNECT FLEXIBLE HOSE (a) Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. (b) Use a container to catch the brake fluid as it drains out. 2. REMOVE CALIPER (a) Remove the installation bolt. (b) Remove the caliper from the torque plate. BR–48 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 3. REMOVE 2 PADS Remove the inside and outside pads. 4. REMOVE MAIN PIN Loosen the. main pin installation bolt and remove the main pin. CALIPER DISASSEMBLY 1. REMOVE SLIDING BUSHING Pull out the sliding bushing. 2. REMOVE MAIN PIN BOOT Pull out the main pin boot. 3. REMOVE DUST BOOTS (a) Place the caliper in vise. (b) Using a screwdriver and hammer, tap out the 2 dust boots. BR–49 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 4. REMOVE CYLINDER BOOT SET RING AND CYLIN– DER BOOT Using a screwdriver, remove the cylinder boot set ring and cylinder boot from the cylinder. 5. REMOVE PISTON (a) Place a piece of cloth or similar article between the piston and the caliper. (b) Use compressed air to remove the piston from the cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed air. 6. REMOVE PISTON SEAL Using a screwdriver, remove the piston seal from the cylinder. REAR DISC BRAKE COMPONENTS INSPECTION AND REPAIR 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad’s thickness is at the mini– mum thickness or less, or if the pad has excessively uneven wear. BR–50 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 9.0 mm (0.354 in.) Replace the disc if the disc’s thickness is at the mini– mum thickness or less. Replace the disc or grind it on a lathe if it is badly scored or worn unevenly. 3. MEASURE DISC RUNOUT Measure the disc runout 10 mm (0.39 in.) from the outer edge of the disc. Maximum disc runout: 0.15 mm (0.0059 in.) If the runout is greater than the maximum, replace the disc. HINT: Before measuring the runout, confirm that the hub bearing play is within specification. 4. IF NECESSARY, REPLACE DISC (a) Remove the torque plate. (b) Remove the hub nuts of the temporarily installed disc and pull off the disc. (c) Install a new disc and loosely install the hub nuts. (d) Install the torque plate and tighten the mounting bolts. Torque: 47 N–m (475 kgf–cm, 34 ft–lbf) CALIPER ASSEMBLY 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO PARTS INDICATED WITH ARROWS 2. INSTALL PISTON SEAL AND PISTON IN CYLINDER BR–51 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 3. INSTALL CYLINDER BOOT AND SET RING IN CYL– INDER 4. INSTALL DUST BOOTS (a) Place the caliper in vise. (b) Using a 19 mm socket wrench and hammer, tap in 2 new dust boots into the torque plate. (c) Confirm that the metal plate portion of the dust boot fits snugly in the torque plate. 5. INSTALL MAIN PIN BOOT 6. INSTALL SLIDING BUSHING CALIPER INSTALLATION 1. INSTALL MAIN PIN Install the main pin and torque the main pin installa– tion bolt. Torque: 26 N–m (270 kgf–cm. 20 ft–lbf) BR–52 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 2. INSTALL 2 PADS Install 2 pads with the pad wear indicator plate facing upward. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. 3. INSTALL CALIPER Install the caliper and torque the installation bolt. Torque: 20 N–m (200 k9f¿cm, 14 ft–lbf) 4. CONNECT FLEXIBLE HOSE Install the flexible hose on the caliper with 2 new gaskets. Torque: 29 N–m (300 kgf–cm, 21 ft–Ibf) HINT: Insert the flexible hose lock securely in the lock hole in the caliper. 5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 6. CHECK FOR LEAKS BR–53 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) REAR BRAKE (Parking Brake for Rear Disc Brake) COMPONENTS PARKING BRAKE DISASSEMBLY 1. REMOVE REAR WHEEL 2. REMOVE REAR DISC BRAKE ASSEMBLY (a) Remove the 2 mounting bolts and remove the disc brake assembly. (b) Suspend the disc brake so the hose is not stretched. 3. REMOVE DISC HINT: If the disc cannot be removed easily, turn the shoe adjuster BR–54 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 4. REMOVE SHOE RETURN SPRINGS Using needle–nose pliers, remove the shoe return springs. 5. REMOVE FRONT SHOE, ADJUSTER AND TENSION SPRING (a) Slide out the front shoe and remove the shoe adjuster. (b) Remove the shoe strut with the spring. (c) Disconnect the tension spring and remove the front shoe. 6. REMOVE REAR SHOE (a) Slide out the rear shoe. (b) Remove the tension spring from the rear shoe. (c) Using needle–nose pliers, disconnect the parking brake cable from the parking brake shoe lever. (d) Remove the shoe hold–down spring cups, springs and pins. PARKING BRAKE COMPONENTS INSPECTION AND REPAIR 1. INSPECT DISASSEMBLED PARTS Inspect the disassembled parts for wear, rust or damage. BR–55 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 2. MEASURE BRAKE SHOE LINING THICKNESS Using a scale, measure the thickness of the shoe lining. Standard thickness: 2.0 mm (0.079 in.) Minimum thickness: 1.0 mm (0.039 in.) If the lining thickness is at the minimum thickness or less, or if there is excessively uneven wear, replace the brake shoe. 3. MEASURE DISC INSIDE DIAMETER Using a vernier caliper, measure the inside diameter of the disc. Standard inside diameter: 170 mm (6.69 in.) Maximum inside diameter: 171 mm (6.73 in.) Replace the disc if the inside diameter is at the maxi– mum value or more. Replace the disc or grind it with a lathe if the disc is badly scored or worn unevenly. 4. INSPECT PARKING BRAKE LINING AND DISC FOR PROPER CONTACT Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit. If the contact between the disc and the brake shoe lining is improp– er, repair it using a brake shoe grinder or replace the brake shoe assembly. 5. MEASURE CLEARANCE BETWEEN PARKING BRAKE SHOE AND LEVER Using a feeler gauge, measure the clearance. Standard clearance: Less than 0.35 mm (0.0138 in.) If the clearance is not within the specification, replace the shim with one of the correct size. Shim Thickness Shim Thickness 0.3 mm (0.012 in.) 0.9 mm (0.035 in.) 0.6 mm (0.024 in.) BR–56 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 6. IF NECESSARY, REPLACE SHIM (a) Remove the parking brake lever, and install the cor– rect size shim. (b) Install the parking brake lever with a new C–washer. (c) Remeasure the clearance. PARKING BRAKE ASSEMBLY HINT: Assemble the parts in the correct direction as shown. BR–57 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 1. APPLY HIGH TEMPERATURE GREASE ON BACK– ING PLATE 2. APPLY HIGH TEMPERATURE GREASE TO ADJUSTER 3. CONNECT PARKING BRAKE CABLE TO PARKING BRAKE LEVER (a) Install the shoe hold–down springs, cups and pins. (b) Using needle–nose pliers, connect the parking brake cable to the parking brake lever. 4. INSTALL REAR SHOE Slide in the rear shoe between the shoe hold–down spring cup and the backing plate. NOTICE: Do not allow oil or grease to get on the rubbing faces. 5. INSTALL TENSION SPRING, FRONT SHOE, AD– JUSTER AND STRUT (a) Install the tension spring to the rear shoe. (b) Install the front shoe to the tension spring. (c) Install the adjuster between the front and rear shoes. BR–58 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) (d) Install the shoe strut with the spring. (e) Slide in the front shoe between the shoe hold–down spring cup and the backing plate. 6. INSTALL SHOE RETURN SPRINGS Using needle–nose pliers, install the shoe return spr– ings. 7. INSTALL DISC (a) Before installing, polish the disc and shoe surfaces with sandpaper. (b) Align the hole on the rear axle hub flange and service hole on the disc. 8. ADJUST PARKING BRAKE SHOE CLEARANCE (a) Temporarily install the hub nuts. (b) Remove the hole plug. (c) Turn the adjuster and expand the shoes until the disc locks. (d) Return the adjuster 8 notches. (e) install the hole plug. BR–59 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 9. INSTALL DISC BRAKE ASSEMBLY Install the disc brake assembly and torque the 2 mot nting bolts. Torque: 47 N–m (475 kgf–cm, 34 ft–lbf) 10. INSTALL REAR WHEEL 11. SETTLING PARKING BRAKE SHOES AND DISC (a) LEVER TYPE: With the parking brake release button pushed in, pull the lever with 98 N (10 kgf, 22 lbf) of force. (b) PEDAL TYPE: Depress the parking brake pedal with 147 N (15 kgf, 33 lbf). (c) Drive the vehicle at about 50 km/h (31 mph) on a safe, level and dry road. (d) Drive the vehicle for about 400 meters (0.25 mile) in this condition. (e) Repeat this procedure 2 or 3 times. 12. RECHECK AND ADJUST PARKING BRAKE LEVER/ PEDAL TRAVEL BR–60 BRAKE SYSTEM – PARKING BRAKE PARKING BRAKE PARKING BRAKE PEDAL DISASSEMBLY AND ASSEMBLY Remove and install the parts as shown. MAIN POINT OF PEDAL INSTALLATION INSTALL SHOCK ABSORBER (a) Loosen the union lock nut. (b) Install the shock absorber to the pin on the pedal bracket side, then extend the piston rod fully. (c) Return the pedal until it hits the cushion. (d) Make adjustments so that the shock absorber’s union and the pin on the pedal side are aligned, then turn the union 1 turn counterclockwise. (e) Install the shock absorber to the pedal and tighten the lock nut. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) BR–61 BRAKE SYSTEM – PARKING BRAKE PARKING BRAKE INTERMEDIATE LEVER DISASSEMBLY AND ASSEMBLY Remove and install the parts as shown. MAIN POINT OF INTERMEDIATE LEVER INSTALLATION MEASURE CLEARANCE BETWEEN INTERMEDIATE LEVER SHAFT AND LEVER Using a feeler gauge, measure the clearance. Standard clearance: 0.09–0.5 mm (0.004–0.02 in.) If the clearance is not within the specification, replace the shim with one of the correct size. Shim Thickness Shim Thickness 0.3 mm (0.012 in.) 1.2 mm (0.047 in.) 0.6 mm (0.024 in.) 1.5 mm (0.059 in.) 0.9 mm (0.035 in.) 1.8 mm (0.071 in.) BR–62 BRAKE SYSTEM – PROPORTIONING VALVE (P VALVE) PROPORTIONING VALVE (P VALVE) P VALVE INSPECTION 1. CONNECT FLUID PRESSURE GAUGE TO P VALVE 2. BLEED AIR FROM FLUID ’PRESSURE GAUGE 3. RAISE MASTER CYLINDER PRESSURE AND CHECK REAR WHEEL CYLINDER PRESSURE Master cylinder fluid pressure Rear brake cylinder fluid pressure 5S–FE w/o ABS: 2,452 kPa (25 kgf/cm2 , 356 psi) 7,845 kPa (80 kgf/cm2 , 1,138 psi) 2,452 kPa (25 kgf/cm2 , 356 psi) 4,452 kPa (45.4 kgf/cm2 , 648 psi) 1 MZ–FE w/o A6S: 2,942 kPa–(30 kgf/cm2 , 427 psi) 2,942 kPa (30 kgf/cm2 , 427 psi) 7,845 kPa (80 kgf/cm2 , 1,138 psi) 4,756 kPa (48.5 kgf/cm2 , 690 psi) 5S–FE w/ABS, 1 MZ–FE w/ABS: 3,432 kPa (35 kgf/cm2 , 498 psi) 7,845 kPa (80 kgf/cm2 , 1,138 psi) 3,432 kPa (35 kgf/cm2 , 498 psi) 5,070 kPa (51.7 kgf/crn2 , 735 psi) If the rear brake cylinder pressure is incorrect, replace the P valve assembly. 4. BLEED BRAKE SYSTEM 5. CHECK FOR LEAKS BR–63 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) LOAD SENSING PROPORTIONING VALVE (LSPV) COMPONENTS FLUID PRESSURE INSPECTION 1. SET REAR AXLE LOAD (a) Set the vehicle to its curb weight. (b) Measure the rear axle load and note the value. (c) Set the rear axle load. Rear axle load: Rear axle curb weight + 31 kg (68 Ib) 2. INSTALL LSPV GAUGE (SST) AND BLEED BRAKE SYSTEM SST 09709–.29017 BR–64 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) 3. RAISE FRONT BRAKE FLUID PRESSURE TO FOL– LOWING SPECIFICATION AND CHECK REAR BRAKE FLUID PRESSURE Rear brake fluid pressure: 5S–FE All, 1 MZ–FE w/ABS Front brake fluid pressure kPa (kgf/cm2 , psi) 9,807 (100, 1,422) Rear brake fluid pressure kPa (kgf/cm2 , psi) 6,139–7,120 (62.6–72.6, 890–1,033) 1 MZ–FE w/o A6S Front brake fluid pressure kPa (kgf/cm2 , psi) 12,747 (130 , 1,849) Rear brake fluid pressure kPa (kgf/cm2 , psi) 8,865–9,846 (90.4–100.4,1,286–1,428) HINT: • Depress the brake pedal while the engine is run– ning. • The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear pressure 2 sec– onds after adjusting to the specified fluid pres– sure. 4. IF NECESSARY, ADJUST FLUID PRESSURE (a) Set the shaft length A to initial set length and tighten the adjusting bolt lock nut. Initial set length: 26.0 mm (1.02 in.) (b) Check the rear brake fluid pressure. (c) If not within the specification, adjust the fluid pres– sure by changing the shaft length. Low pressure–Lengthen A High pressure–Shorten A HINT:–For every full turn of the adjusting nut, the fluid pressure will change as follows: Fluid Pressure changed kPa (kgf/cm2, psi) 5S–FE All, 1 MZ–FE w/ABS 294 (3.0, 42.7) 1 MZ–FE w/o ABS 422 (4.3, 61.2) BR–65 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) (d) Torque the lock nut. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) If it cannot be adjusted, replace the valve body. LSPV REMOVAL 1. DISCONNECT BRAKE LINES Using SST, disconnect the brake lines from the valve body. SST 09751–36011 2. REMOVE LSPV ASSEMBLY (a) Remove the lock nut and disconnect the adjusting bolt from the rear suspension arm. (b) Remove the 2 mounting bolts and remove the LSPV assembly. LSPV INSTALLATION 1. INSTALL LSPV ASSEMBLY (a) Install the valve assembly with the 2 mounting bolts. Torque: 39 N–m (400 kgf–cm, 29 ft–lbf) (b) Install the adjusting nut to the adjusting bolt and then install the adjusting bolt to the rear suspension arm with the lock nut. BR–66 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) 2. CONNECT BRAKE LINES Using SST, connect the brake lines. SST 09751–36011 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 3. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 4. CHECK FOR LEAKS 5. CHECK AND ADJUST FLUID PRESSURE (See page BR–63) 6. REMOVE LSPV GAUGE (SST) AND BLEED BRAKE SYSTEM 7. CHECK FOR LEAKS BR–67 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ANTI–LOCK BRAKE SYSTEM (ABS) DESCRIPTION • ABS controls the brake cylinder hydraulic pressure to all 4 wheels during sudden braking and braking on slippery road surfaces, preventing the wheels from locking. ABS provides the following benefits: (1) Steering round an obstacle with a greater degree of certainty even when panic braking. (2) Stopping during panic braking while keeping the effect up on stability and steerability to a minimum, even on curves. • In case a malfunction occurs, a diagnosis function and fail–safe system have been adopted for the ABS. • An ABS actuator manufactured by BOSCH is used on the Camry produced by TMM (Toyota Motor Manufacturing U.S.A., Inc.). BR–68 BRAKE SYSTEM SYSTEM PARTS LOCATION – ANTI–LOCK BRAKE SYSTEM (ABS) BR–69 BRAKE SYSTEM WIRING DIAGRAM TMC Made Vehicle/NIPPONDENSO ABS: – ANTI–LOCK BRAKE SYSTEM (ABS) BR–70 BRAKE SYSTEM WIRING DIAGRAM TMM Made Vehicle/BOSCH ABS: – ANTI–LOCK BRAKE SYSTEM (ABS) BR–71 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS TMC Made Vehicle/NIPPONDENSO ABS: Terminal No. Connection Symbol Right front solenoid Terminal No. Connection Symbol Left rear speed sensor Ground Right front speed sensor DLC2 DLC1, DLC2 ABS control (motor) relay monitor Stop light switch Sealed wiring harness Right rear speed sensor Left front speed sensor Left rear speed sensor Sealed wiring harness ABS control (solenoid) relay Ignition switch Left front solenoid Left rear solenoid Ground Right front speed sensor A8S control (solenoid) relay monitor Left front speed sensor ABS control (motor) relay Relay ground Battery Right rear solenoid ABS warning light Parking brake switch DLC1 Right rear speed sensor BR–72 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS TMM Made Vehicle/BOSCH ABS: Terminal No. Connection Symbol Terminal No. Symbol Connection A6S warning fight Battery Left rear speed sensor Ignition switch DLC1 Left rear speed sensor Right front speed sensor Right rear speed sensor Left front speed sensor Stop light switch Right front speed sensor DLC1, DLC2 Left front speed sensor Right rear speed sensor DLC1 Ground BR–73 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS STANDARD VALUE TMC Made Vehicle/NIPPONDENSO ABS: Symbols (Terminals No.) STD Voltage (V) Condition Always IG switch ON IG switch ON, ABS warning light OFF IG switch ON IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF IG switch ON, AIRS warning light ON IG switch ON, ABS warning light OFF IG switch ON, PKB switch ON, Fluid in M/C reservoir above MIN level IG switch ON, PKB switch OFF, Fluid in M/C reservoir above MIN level Stop light switch OFF Stop light switch ON IG switch ON, ABS warning light OFF !G switch ON lG switch ON AC generation IG switch ON Slowly turn right front wheel AC generation IG switch ON Slowly turn left front wheel AC generation IG switch ON Slowly turn right rear wheel AC generation IG switch ON Slowly turn left rear wheel BR–74 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS STANDARD VALUE TMM Made Vehicle/BOSCH ABS: Symbols (Terminals No.) STD Voltage (V) Condition Always IG switch ON IG switch ON, A6S warning light ON IG switch ON, ABS warning light OFF IG switch ON, ABS warning light ON IG switch ON, ABS warning light OFF Stop light switch OFF Stop light switch ON lG switch ON I G switch 0 N AC generation IG switch ON, slowly turn right front wheel AC generation IG switch ON, slowly turn left front wheel AC generation IG switch ON, slowly turn right rear wheel AC generation IG switch ON, slowly turn left rear wheel BR–75 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR (TMC Made Vehicle NIPPONDENSO ABS) ABS ACTUATOR REMOVAL AND INSTALLATION Remove and install the parts as shown. BR–76 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) MAIN POINTS OF REMOVAL AND INSTALLATION 1. DISCONNECT AND CONNECT BRAKE LINE Using SST, disconnect and connect the brake lines from/to the ABS actuator. SST 09023–00100 Torque: 15 N–m (155 kgf–cm. 11 ft–lbf) 2. BLEED BRAKE SYSTEM (See page BR–9) BR–77 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR INSPECTION 1. INSPECT BATTERY POSITIVE VOLTAGE Battery positive voltage: 10–14.5 V 2. DISCONNECT CONNECTORS (a) Disconnect the connector from the actuator. (b) Disconnect the 2 connectors from the control relay. 3. CONNECT ACTUATOR CHECKER (SST) TO ACTUA– TOR (a) Connect the actuator checker (SST) to the actuator, control relay and body side wire harness through the sub–wire harness C and E (SST) as shown. SST 09990–00150, 09990–00200, 09990–00210 (b) Connect the red cable of the checker to the battery positive (+) terminal and black cable to the negative (–) terminal. Connect the black cable of the sub–wire harness to the battery negative (–) terminal or body ground. BR–78 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) (c) Place the ”SHEET A” (SST) on the actuator checker. SST 09990–00163 4. INSPECT BRAKE ACTUATOR OPERATION (a) Start the engine, and run it at idle. (b) Turn the selector switch of the actuator checker to ”FRONT RH” position. (c) Push and hold in the MOTOR switch for a few sec– onds. (d) Depress the brake pedal and hold it until step (g) is com pleted. (e) Push the POWER SWITCH, and check that the brake pedal does not go down. NOTICE: Do not keep the POWER SWITCH pushed down for more than 10 seconds. (f) Release the switch, and check that the pedal goes down. – (g) Push and hold in the MOTOR switch for a few sec onds, and check that the pedal returns. (h) Release the brake pedal. (i) Push and hold in the MOTOR switch for a few sec– onds. (j) Depress the brake pedal and hold it for about 15 seconds. As you hold the pedal down, push the MOTOR switch for a few seconds. Check that the brake pedal does not pulsate. (k) Release the brake pedal. BR–79 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) (l) Turn the selector switch to ”FRONT LH” position. (m) Repeat (c) to 6), checking the actuator operation sim– ilarly. (n) Similarly, inspect ”REAR RH” and ”REAR LH” position. HINT: When inspecting ”REAR LH” position, push the REAR LH switch instead of the POWER SWITCH, and you can inspect in any selector switch position. (o) Push and hold in the MOTOR switch for a few sec– onds. (p) Stop the engine. 5. DISCONNECT ACTUATOR CHECKER (SST) FROM ACTUATOR Remove the ”SHEET A” (SST) and disconnect the actuator checker (SST) and sub–wire harness (SST) from the actuator, control relay and body side wire harness. SST 09990–00150, 09990–00200, 09990–00210 , 09990–00163 6. CONNECT CONNECTORS (a) Connect the 2 connectors to the control relay. (b) Connect the connector to the actuator. 7. CLEAR DIAGNOSTIC TROUBLE CODES (See page BR–94) BR–80 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR (TMM Made Vehicle BOSCH ABS) ABS ACTUATOR REMOVAL AND INSTALLATION Remove and install the parts as shown. BR–81 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) MAIN POINTS OF REMOVAL AND INSTALLATION 1. DISCONNECT AND CONNECT BRAKE LINE Using SST, disconnect and connect the brake lines from/to the ABS actuator. SST 09751–36011 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 2. INSTALL ABS ACTUATOR NOTICE: Use the bolts which have a notch to securely ground the actuator ground wire. 3. BLEED BRAKE SYSTEM (See page BR–9) BR–82 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR DISASSEMBLY AND ASSEMBLY Remove and install the parts as shown. BR–83 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) MAIN POINTS OF DISASSEMBLY AND ASSEMBLY 1. REMOVE AND INSTALL COVER Using a T15 torx wrench, loosen and tighten the screw. Torque: 1.4 N–m(14 kgf–cm, 12 in.lbf) 2. DISCONNECT AND CONNECT 4–PIN AND 6–PIN CONNECTORS NOTICE: When installing, place the 4–pin connector’s cables into the cable guide. 3. REMOVE AND INSTALL ECU Using T15 and T20 torx wrenches, loosen and tighten the 5 screws. Torque: 1.7 N–m(17 kgf–cm, 15 in.–Ibf) NOTICE: There are 2 kinds of screw, so install a correct screw into each hole. 4. PERFORM TEST DRIVE (a) Drive for at least 20 seconds at 30 Km/h (119 mph). (b) The ABS warning light may not light. If the ABS warning light lights, read the diagnostic trouble code. BR–84 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) FRONT SPEED SENSOR COMPONENTS FRONT SPEED SENSOR AND SENSOR ROTOR SERRATIONS INSPECTION (REFERENCE) INSPECT FRONT SPEED SENSOR AND SENSOR ROTOR SERRATIONS BY USING AN OSCILLO– SCOPE (a) Connect an oscilloscope to the speed sensor connec– tor. (b) Run the vehicle at 20 km/h (112.4 mph), and inspect speed sensor output wave. (c) Check that C is 0.5 V or more. If not as specified, replace the speed sensor. (d) Check that B is 30% or more of A. If not as specified, replace the drive shaft. FRONT SPEED SENSOR REMOVAL 1. DISCONNECT SPEED SENSOR CONNECTOR (a) Remove the fender shield. (b) Disconnect the speed sensor connector. BR–85 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) 2. REMOVE SPEED SENSOR (a) Remove the 3 clamp bolts holding the sensor harness to the body and shock absorber_ (b) Remove the speed sensor from the steering knuckle. FRONT SPEED SENSOR INSTALLATION 1. INSTALL SPEED SENSOR Install the speed sensor to the steering knuckle. Torque: 7.8 N–m (80 kgf–cm, 69 in.–lbf) 2. CONNECT SPEED SENSOR CONNECTOR (a) Install the sensor harness. Torque: 5.4 N–m (55 kgf–cm. 48 in.–lbf) (b) Connect the speed sensor connector. ¿¿”–07 BR–86 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) REAR SPEED SENSOR COMPONENTS REAR SPEED SENSOR AND SENSOR ROTOR SERRATIONS INSPECTION (REFERENCE) INSPECT REAR SPEED SENSOR AND SENSOR ROTOR SERRATIONS BY USING AN OSCILLO– SCOPE (a) Connect an oscilloscope to the speed sensor connec– tor. (b) Run the vehicle at 20 km/h (12.4 mph), and inspect speed sensor output wave. (c) Check that C is 0.5 V or more. If not as specified, replace the speed sensor. (d) Check that B is 40 96 or more of A. If not as specified, replace the rear axle hub. BR–87 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) REAR SPEED SENSOR REMOVAL 1. DISCONNECT SPEED SENSOR CONNECTOR (a) Remove the seat cushion and side seatback. (b) Disconnect the speed sensor connector, and pull out the sensor wire harness with the grommet. (c) Remove the 2 clamp bolts holding the sensor wire harness to the body and shock absorber. 2. REMOVE SPEED SENSOR Remove the speed sensor from the axle carrier. REAR SPEED SENSOR INSTALLATION 1. INSTALL SPEED SENSOR Install the speed sensor to the axle carrier. Torque: 7.8 N–m (80 kgf–cm, 69 in.lbf) 2. CONNECT SPEED SENSOR CONNECTOR (a) Pass the sensor harness through the body panel hole, and connect the connector. BR–88 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) (b) install the grommet securely. (c) Install the sensor harness. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) BR–89 BRAKE SYSTEM –MEMO– – ANTI–LOCK BRAKE SYSTEM (ABS) BR–90 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING (TMC Made Vehicle NIPPONDENSO ABS) HOW TO PROCEED WITH TROUBLESHOOTING Perform troubleshooting in accordance with the procedure on the following pages. (1) CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in as much detail as possible about the problem. (2) CHECK AND CLEAR THE DIAGNOSTIC TROUBLE CODES (PRECHECK) If the ABS warning light lights up, and the ABS does not operate, the ECU stores diagnostic trouble codes corresponding to the problem in memory. Before confirming the trouble, first check the diagnostic trouble codes to see if there are any malfunction codes stored in memory. When there are malfunction codes, make a note of them, then clear them and proceed to ”3” Problem Symptom Confirmation”. (3) PROBLEM SYMPTOM CONFIRMATION, (4) SYMPTOM SIMULATION Confirm the problem symptoms. If the problem does not recur, simulate the problem by initially checking the circuits indicated by the diagnostic trouble code in step “2” , using ”Problem simulation method”. (5) DIAGNOSTIC TROUBLE CODE CHECK Check the diagnostic trouble codes. If a malfunction code is output, proceed to ” 6” Diagnostic Trouble Code Chart”. If the normal code is output, proceed to ” 7” Problem Symptoms Chart”. Be sure to proceed to ” 6” Diagnostic Trouble Code Chart” after steps “2” and “3” are completed. If troubleshooting is attempted only by following the malfunction code stored in the memory, errors could be made in the diagnosis. (6) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is confirmed in the diagnostic trouble code check, proceed to the inspection procedure indicated by the matrix chart for each diagnostic trouble code. (7) PROBLEM SYMPTOMS CHART If the normal code is confirmed in the diagnostic trouble code check, perform inspection in accordance with the inspection order in the problem symptoms chart. (8) CIRCUIT INSPECTION Proceed with diagnosis of each circuit in accordance with the inspection order confirmed in 6 and 7 . Determine whether the cause of the problem is in the sensor, actuators, wire harness and connectors, or the ECU. (9) SENSOR CHECK Use the ABS warning light to check if each of the signals from the speed sensors are being input correctly to the ECU. Instructions for this check are given in the circuit inspection. (10) REPAIRS After the cause of the problem is located, perform repairs by following the inspection and replacement procedures in this manual. (11) CONFIRMATION TEST After completing repairs, confirm not only that the malfunction is eliminated, but also conduct a test drive to make sure the entire ABS system is operating correctly. BR–91 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Items inside are titles of pages in this manu– al, with the page number in the bottom portion. See the pages for detailed explanations. Vehicle brought to workshop Customer Problem Analysis P. BR–92 2 Check and Clear Diagnostic Trouble Code Precheck) P. BR–93BR–94 Symptom does not occur 3 Problem Symptom Confirmation Symptom Simulation P.!N–21 Symptom occurs 5 Normal code Diagnostic Trouble Code Check P. BR–93 6 Diagnostic Trouble Code Chart Problem Symptoms Chart P. BR–95 Circuit Inspection P. BR–98 Sensor Check Check for Fluid Leakage P. BR–108BR–138 P. BR–139 Identification of Problem 10 Repair Confirmation Test End Step 5 8 Diagnostic steps permitting the use of the TOYOTA hand–held tester or TOYOTA break–out–box. BR–92 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) CUSTOMER PROBLEM ANALYSIS CHECK SHEET BR–93 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSIS SYSTEM INDICATOR CHECK When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. HINT: If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit (See page BR– 130). DIAGNOSTIC TROUBLE CODE CHECK 1. Disconnect the Short Pin from DLC1. 2. Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 09843–18020 3. Turn the ignition switch to ON. 4. Read the diagnostic trouble code from the ABS warning light on the combination meter. HINT: If no code appears, inspect the diagnostic circuit or ABS warning light circuit (See page BR–134 or BR–130). As an example, the blinking patterns for normal code and codes 11 and 21 are shown on the left. 5. Codes are explained in the code table on page BR–95. 6. After completing the check, disconnect terminals Tc and E1, and turn off the display. If 2 or more malfunctions are indicated at the same time, the–lowest numbered diagnostic trouble code will be displayed first. . BR–94 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Hook up the Toyota hand–held tester to the DLC2. 2. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the Toyota hand–held tester operator’s manual for further details. DIAGNOSTIC TROUBLE CODE CLEARANCE 1. Using SST, connect terminals Tc and E1 of DLC2 or DLC1 and remove the short pin from DLC1. SST 09843–18020 2. IG switch ON. 3. Clear the diagnostic trouble codes stored in ECU by de– pressing the brake pedal 8 or more times within 3 seconds. 4. Check that the warning light shows the normal code. 5. Remove the SST from the terminals of DLC2 or DLC1. 6. Connect the Short Pin to DLC1 HINT: Cancellation can also be done by removing the ECU–13 fuse, but in this case, other memory systems will also be cancelled out. ECU TERMINAL VALUES MEASUREMENT USING TOYOTA BREAK–OUT–BOX AND TOYOTA HAND–HELD TESTER 1. Hook up the Toyota break–out–box and Toyota hand–held tester to the vehicle. 2. Read the ECU input/output values by following the prompts on the tester screen. HINT: Toyota hand–held tester has a ”Snapshot” function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the Toyota hand–held tester/Toyota break– out–box operator’s manual for further details. BR–95 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check, check the circuit listed for that code. HINT: Using SST 09843–18020, connect the terminals Tc and E1, and remove the short pin. Code ABS Warning Light Blinking Pattern Diagnosis Open circuit in ABS control (solenoid) relay circuit Short circuit in ABS control (solenoid) relay circuit Open circuit in ABS control (motor) relay circuit Short circuit in ABS control (motor) relay circuit Open or short circuit in 3–position solenoid circuit for right front wheel Open or short circuit in 3–position solenoid circuit for left front wheel Open or short circuit in 3–position solenoid circuit for right rear wheel Open or short circuit in 3–position solenoid circuit for left rear wheel Right front wheel speed sensor signal malfunction Left front wheel speed sensor signal malfunction Right rear wheel speed sensor signal malfunction Left rear wheel speed sensor signal malfunction Open circuit in left front or right rear speed sensor circuit Open circuit in right front or left rear speed sensor circuit Faulty rear speed sensor rotor Low battery positive voltage or abnormally high battery positive voltage Pump motor is locked Open in pump motor ground Always ON Malfunction in ECU BR–96 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) SPEED SENSOR SIGNAL CHECK 1. Turn the ignition switch to OFF. 2. Using SST, connect terminals Ts and E1 of DLC1. SST 09843–18020 3. Start the engine. 4. Check that the ABS warning light blinks HINT: If the ABS. warning light does not blink, inspect the ABS warning light circuit (See page BR–130). 5. Drive vehicle straight forward. HINT: Drive vehicle faster than 45 km/h (28 mph) for several seconds. 6. Stop the vehicle. 7. Using SST, connect terminals Tc and E1 of DLC1. SST 09843–18020 8. Read the number of blinks of the ABS warning light. HINT: See the list of diagnostic trouble codes shown on the next page. If every sensor is normal, a normal code is output (A cycle of 0.25 sec. ON and 0.25 sec. OFF is repeated). If 2 or more malfunctions are indicated at the same time, the lowest numbered code will be displayed first. 9. After performing the check, disconnect terminals Ts and E1, Tc and E1 of DLC1, and ignition switch turned off. BR–97 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Perform steps 1.–6. on the previous page. 2. Hook up the Toyota hand–held tester to the DLC2. 3. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the Toyota hand–held tester operator’s manual for further details. Diagnostic Trouble Code of Speed Sensor Check Function Code No. Diagnosis Trouble Area Low output voltage of right front speed sensor • • Right front speed sensor Sensor installation Low output voltage of left front speed sensor • • Left front speed sensor Sensor installation Low output voltage of right rear speed sensor • • Right rear speed sensor Sensor installation Low output voltage of left rear speed sensor • • Left rear speed sensor Sensor installation Abnormal change in output voltage of right front speed sensor • Right front speed sensor rotor Abnormal change in output voltage of left front speed sensor • Left front speed sensor rotor Abnormal change in output voltage of right rear speed sensor • Right rear speed sensor rotor Abnormal change in output voltage of left rear speed sensor • Left rear speed sensor rotor BR–98 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) PROBLEM SYMPTOMS CHART If a normal code is displayed during the diagnostic trouble code check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. Inspection Circuit Symptoms A6S does not operate. A6S does not operate efficiently. ABS warning light abnormal. Diagnostic trouble code check cannot be performed. Speed sensor signal check cannot be performed. Only when 1.–4. are all normal and the problem is still occurring, replace the ABS ECU. 1. Check the diagnostic trouble code, reconfirming that the normal code is output. 2. IG power source circuit. 3. Speed sensor circuit. 4. Check the ABS actuator with a checker. If abnormal, check the hydraulic circuit for leakage (see page BR–139). Only when 1.–4. are all normal and the problem is still occurring, replace the ABS ECU. 1. Check the diagnostic trouble code, reconfirming that the normal code is output. 2. Speed sensor circuit. 3. Stop light switch circuit. 4. Check the ABS actuator with a checker. If abnormal, check the hydraulic circuit for leakage (see page BR–139). 1. ABS warning light circuit. 2. ABS ECU. Only when 1. and 2. are all normal and the problem is still occurring, replace the ABS ECU. 1. ABS warning light circuit. 2. Tc terminal circuit. 1. Ts terminal circuit. 2. ABS ECU. See page BR–93 BR–123 BR–119 BR–77 BR–93 BR–119 BR–128 BR–77 BR–130 BR–130 BR–134 BR–137 BR–99 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) LOCATION OF CONNECTORS Location of Connectors in Engine Compartment 1MZ–FE Engine: BR–100 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–101 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in Engine Compartment 5S–FE Engine: BR–102 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–103 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in Instrument Panel BR–104 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–105 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–106 BRAKE SYSTEM – J/B No. 1 J/B No. 3 ANTI–LOCK BRAKE SYSTEM (ABS) BR–107 BRAKE SYSTEM Location of Connectors in Body – ANTI–LOCK BRAKE SYSTEM (ABS) BR–108 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) CIRCUIT INSPECTION DTC 11,12 ABS Control (Solenoid) Relay Circuit CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. DTC No. Diagnostic Trouble Code Detecting Condition Conditions (1) and (2) continue for 0.2 sec. or more: (1) ABS control (solenoid) relay terminal (SR) voltage: Battery positive voltage (2) ABS control (solenoid) relay monitor termi– nal (AST) voltage: 0 V Conditions (1) and (2) continue for 0.2 sec. or more: (1) ABS control (solenoid) relay terminal (SR) voltage: 0 V (2) ABS control (solenoid) relay monitor termi– nal (AST) voltage: Battery positive voltage Trouble area • • • ABS control (solenoid) relay. Open or short in ABS control (solenoid) relay circuit. ECU. • • • ABS control (solenoid) relay. B+ short in ABS control (solenoid) relay circuit. ECU. Fail safe function: If trouble occurs in the control (solenoid) relay circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. DIAGNOSTIC CHART Check voltage of ABS control relay connector. Check and repair harness or connector. Check continuity between relay and actuator and ECU. Repair or replace harness or ABS ac– tuator. Check ABS control relay. Replace ABS control relay. Check for open and short in harness and con– nector between relay and ECU. Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–109 BRAKE SYSTEM WIRING DIAGRAM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–110 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 2 and Check voltage between terminals connector. 6 of ABS control relay Disconnect the ABS control relay connector. Measure voltage between terminals A72 and A76 of ABS control relay harness side connec– tor. Voltage: 10–14 V Check and repair harness or connector. Check continuity between terminals A4 2, A4 2 and A13 18. 5 and 4 and Disconnect the 2 connectors from ABS actuator. Check continuity between terminals (A7) 5 and (A5)4, (A5)4 and (A4)2, (A4)2 and (A13)18. Continuity HINT: There is a resistance of 4–6 between terminals A5 4 and A4 2. Repair or replace harness or ABS actuator. BR–111 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check ABS control relay. Check continuity between each terminal of ABS control relay. Continuity (Reference value 80) Terminals 1 and Terminals 5 and Continuity Terminals 2 and Open 1. Apply battery positive voltage between termi– nals A7 1 and A6 3. 2. Check continuity between each terminal of ABS control relay. Terminals Terminals 5 a rid Open 2 and Continuity Replace ABS control relay. Check for open and short in harness and connector between ABS control relay and ABS ECU (See page IN–28). Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–112 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 13,14 ABS Control (Motor) Relay Circuit CIRCUIT DESCRIPTION The ABS control (motor) relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches the control (motor) relay ON and operates the ABS pump motor. DTC No. Diagnostic Trouble Code Detecting Condition Conditions (1) and (2) continued for 0.2 sec. or more: (1) ABS control (motor) relay terminal (MR) voltage: Battery positive voltage (2) ABS control (motor) relay monitor terminal (MT) voltage: 0 V Conditions (1) and (2) continued for 4 sec. or more: (1) ABS control (motor) relay terminal (MR) voltage: 0 V (2) ABS control (motor) relay monitor terminal (MT) voltage: Battery positive voltage Fail safe function: Trouble area • • • ABS control (motor) relay. Open or short in ABS control (motor) relay circuit. ECU. • • • ABS control (motor) relay. B+ short in ABS control (motor) relay circuit. ECU. If trouble occurs in the control (motor) relay circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. DIAGNOSTIC CHART Check voltage of ABS control relay connector. Check and repair harness or connector. Check continuity between relay and pump motor and ECU. Repair or replace harness or ABS ac– tuator. Check ABS control relay. Replace ABS control relay. Check for open and short in harness and con– nector between relay and ECU. Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–113 BRAKE SYSTEM WIRING DIAGRAM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–114 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals ground. 1 of ABS control relay and body Disconnect the ABS control relay connector. Measure voltage between terminals A6 1 of ABS control relay harness side connector and body ground. Voltage: 10–14 V Check and repair harness or connector. Check continuity between terminals A4 5, A4 5 and A13 6. 2 and 3 and Disconnect the 2 connectors from ABS actuator. Check continuity between terminals A6 2 and A5 3, A5 3 and A4 5, A4 5 and A13 6. Continuity HINT: There is a resistance of 4–6 between terminals A5 3 and A4 5. Repair or replace harness or ABS actuator. BR–115 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) Check ABS control relay. Check continuity between each terminal of ABS control relay. Terminals 3 and Continuity (Reference value 62
Terminals 1 and Open 1. Apply battery positive voltage between termi– nals A6 3 and A6 4. 2. Check continuity between each terminal of ABS control relay. Terminals 1 and Continuity Replace ABS control relay. Check for open and short in harness and connector between ABS control relay and ABS ECU (See page IN–28). Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–116 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 21, 22, 23, 24 ABS, Actuator Solenoid Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders, thus controlling the braking force. DTC No. Diagnostic Trouble Code Detecting Condition Conditions (1) through (3) continue for 0.05 sec. or more: (1) ABS control (solenoid) relay terminal (SR) • voltage: Battery positive voltage • (2) Voltage of ABS ECU terminal • AST: Battery positive voltage (3) When power transistor of ECU is ON, voltage of terminal SFR is 0 V or battery positive voltage. Conditions (1) through (3) continue for 0.05 sec. or more: (1) ABS control (solenoid) relay terminal (SR) • voltage: Battery positive voltage • (2) Voltage of ABS ECU terminal • AST: Battery positive voltage (3) When power transistor of ECU is ON, voltage of terminal SFL is 0 V or battery positive voltage. Trouble area ABS actuator. Open or short in SFR circuit. ECU. ABS actuator. Open or short in SFL circuit. ECU. Conditions (1) through (3) continue for 0.05 sec. or more: (1) ABS control (solenoid) relay terminal (SR) • voltage: Battery positive voltage • (2) Voltage of ABS ECU terminal • AST: Battery positive voltage (3) When power transistor of ECU is ON, voltage of terminal SRR is 0 V or battery positive voltage. ABS actuator. Open or short in SRR circuit. ECU. Conditions (1) through (3) continue for 0.05 sec. or more: (1) ABS control (solenoid) relay terminal (SR) • voltage: Battery positive voltage • (2) Voltage of ABS ECU terminal • AST: Battery positive voltage (3) When power transistor of ECU is ON, voltage of terminal SRL is 0 V or battery positive voltage. ABS actuator. Open or short in SRL circuit. ECU. Fail safe function: If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the control (solenoid) relay and prohibits ABS control. DIAGNOSTIC CHART Check ABS actuator solenoid. Replace ABS actuator. Check for open and short in harness and con– nector between ECU and actuator. Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–117 BRAKE SYSTEM WIRING DIAGRAM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–118 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check ABS actuator solenoid. Disconnect the 2 connectors from ABS actuator. Check continuity between terminals A5 4and A4 1, 3, 4, 6 of ABS actuator connector. Continuity HINT: Resistance of each solenoid coil is 1.2. Replace ABS actuator. Check for open and short in harness and connector between ABS ECU and actuator (See page IN–28). Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–119 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 31, 32, 33, 34, 35, 36 Speed Sensor Circuit CIRCUIT DESCRIPTION The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system. The front and rear rotors each have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. DTC No. 31,32, 33,34 Trouble area Diagnostic Trouble Code Detecting Condition Detection of any of conditions (1) through (3): (1) At vehicle speed of 10 km/h (6 mph) or more, pulses are not input for 5 sec. (2) Momentary interruption of the speed sensor signal occurs at least 7 times in the time be– tween switching the ignition switch ON and switching it OFF. (3) Abnormal fluctuation of speed sensor signals with the vehicle speed 20 km/h (12 mph) or more. Speed sensor signal is not input for about 1 sec. while the left front and right rear speed sensor signals are being checked with the IG switch ON. Speed sensor signal is not input for about 1 sec. while the right front and left rear speed sensor signals are being checked with the IG switch ON. • Right front, left front, right rear and left rear speed sensor. Open or short in each speed sensor circuit. ECU. • • • • • Open in left front or right rear speed sensor circuit. ECU. Open in right front or left rear speed sensor circuit. • ECU. HINT: DTC No. 31 is for the right front speed sensor. DTC No. 32 is for the left front speed sensor. DTC No. 33 is for the right rear speed sensor DTC No. 34 is for the left rear speed sensor. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. BR–120 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC CHART Check speed sensor. Replace speed sensor. Check for open and short in harness and con– hector between each speed sensor and ECU. Repair or replace harness or connector. Check sensor rotor and sensor installation. Replace speed sensor or rotor. Check and replace ABS ECU. WIRING DIAGRAM BR–121 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check speed sensor. Front 1. Remove front fender liner. 2. Disconnect speed sensor connector. Measure resistance between terminals 1 and 2 of speed sensor connector. Resistance: 0.6–1.8 k
Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. Resistance: 1 M
or higher Rear 1. Remove the seat cushion and side seat back. 2. Disconnect speed sensor connector. Measure resistance between terminals 1 and 2 of speed sensor connector. Resistance: 0.9–1.3 k
Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. Resistance: 1 M
or higher Replace speed sensor. Check for open and short in harness and connector between each speed sensor and ECU (See page IN–28). Repair or replace harness or connector. BR–122 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check sensor rotor and sensor installation. Front Remove front drive shaft (See SA section). Check sensor–rotor serrations. No scratches or missing teeth. Check the front speed sensor installation The installation bolt is tightened properly. Rear Remove the axle hub (See SA section). Check the sensor rotor serrations. No scratches or missing teeth. Check the speed sensor installation The installation bolt is tightened properly and there is no clearance between the sensor and rear axle carrier. Replace speed speed or rotor. Check and replace ABS ECU. BR–123 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 41 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the CPU and the actuators. DTC No. Trouble area Diagnostic Trouble Code Detecting Condition Vehicle speed is 3 km/h (1.9 mph) or more and voltage of ECU terminal IG1 remains at more than 17 V or below 9.5 V for more than 10 sec. • • • • Battery. IC regulator. Open or short in power source circuit. ECU. Fail safe function: If trouble occurs in the power source circuit, the ECU cuts oft current to the ABS control (solenoid) relay and prohibits ABS control. DIAGNOSTIC CHART Check battery positive voltage. Check and repair the charging system. Check voltage between terminals IG1 and GND of ABS ECU connector. Check and replace ABS ECU. Check continuity between terminals GND of ABS ECU connector and body ground. Repair or replace harness or connector. Check ECU–IG fuse. Check for short in all the harness and components connected to ECU–IG fuse (See attached wiring diagram). Check for open in harness and connector between ABS ECU and battery. BR–124 BRAKE SYSTEM WIRING DIAGRAM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–125 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check battery positive voltage. Voltage: 10–14V Check and repair the charging system, Check voltage between terminals IG1 and GND of ABS ECU connector. Remove ABS ECU with connectors still connected. 1. Turn ignition switch ON. 2. Measure voltage between terminals IG1 and GND of ABS ECU connector. Voltage: 10–14 V Check and replace ABS ECU. Check continuity between terminals GND of ABS ECU connector and body ground. Measure resistance between terminals GND of ABS ECU connector and body ground. Resistance: 1
or less Repair or replace harness or connector. BR–126 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check ECU–IG fuse. Remove ECU–IG fuse from J/6 No. 1. Check continuity of ECU–IG fuse. Continuity Check for short in all the harness and components connected to ECU–IG fuse (See attached wiring diagram). Check for open in harness and connector between ABS ECU and battery (See page IN–28). BR–127 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION DTC No. Diagnostic Trouble Code Detecting Condition Pump motor is not operating normally during initial check. Trouble area • ABS pump motor. Fail safe function: If trouble occurs in the ABS pump motor, the ECU cuts off current to the control (solenoid) relay and prohibits ABS control. DIAGNOSTIC CHART See inspection of ABS actuator (See page BR–77). WIRING DIAGRAM (Reference) BR–128 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Stop Light Switch Circuit CIRCUIT DESCRIPTION This stop light switch senses whether the brake pedal is depressed or released, and sends the signal to the ECU. DIAGNOSTIC CHART Check operation of stop light. Repair stop light circuit (See page BE– 65). Check voltage of terminal STP. Proceed to next circuit inspection shown on problem symptoms chart (See page BR–98). Check for open in harness and connector be– tween ABS ECU and stop light switch (See page IN–27). Repair or replace harness or connector. Check and replace ABS ECU. WIRING DIAGRAM BR–129 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check operation of stop light. Check that stop light lights up when brake pedal is depressed and turns off when brake pedal is released. Repair stop light circuit (See page BE–65). Check voltage between terminal STP of ABS ECU and body ground. Remove ABS ECU with connectors still connected. Measure voltage between terminal STP of ABS ECU and body ground when brake pedal is de– pressed. Voltage: 8–14 V Proceed to next circuit inspection shown on problem symptoms chart (See page BR–98). Check for open in harness and connector between ABS ECU and stop light switch (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. BR–130 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a diagnostic trouble code in memory. After removing the short pin of the DLC1, connect terminals Tc and E1 of the DLC1 or DLC2 to make the ABS warning light to blink and output the diagnostic trouble code. DIAGNOSTIC CHART Perform troubleshooting in accordance with the chart below for each trouble symptom. ABS warning light does not light up G o to step 1 . . ... ABS warning light remains on WIRING DIAGRAM Go to step 3 BR–131 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS warning light does not light up. Check ABS warning light. Repair or replace ABS warning light bulb or circuit. Check ABS control relay. Replace ABS control relay. Check for open in harness and connector between GAUGE fuse and J/B No. 3. A6S warning light remains on. Is diagnostic trouble code output? Does ABS warning light go off if short pin is removed? YES Check ABS control relay. Check for short in harness and connector between DLC1 and ABS control relay. YES Repair circuit indicated by the code output. Check for–short in harness and connec– tor between warning light and DLC1 and ECU. Replace ABS control relay. BR–132 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check ABS warning light. See Combination Meter Troubleshooting on page BE–1 18. Replace bulb or combination meter assembly. Check ABS control relay. Disconnect the connectors from control relay. Check continuity between each terminal of ABS control relay. Terminals 1 and Continuity (Reference value 80) Terminals 5 and Continuity Terminals 2 and Open 1. Apply battery positive voltage between termi– nals A7 1 and A6 3. 2. Check continuity between each terminal of ABS control relay. Terminals Terminals 5 and 2 and Open Continuity Connect the  test lead to terminal 4 of A7 and the  lead to terminal 5 of A7 . Check continuity between the terminals. Continuity If there is no continuity, connect the  test lead to terminal 4 of A7 and the  lead to terminal 5 of A7 . Recheck continuity between terminals. Replace ABS control relay. Check for open in harness and connector between DLC1 and A6S control relay and body ground (See page IN–27). BR–133 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Is diagnostic trouble code output? Perform diagnostic trouble code check on page BR–93. YES Repair circuit indicated by the code output. Does ABS warning light go off if short pin is removed? YES Check for short in harness and connector between warning light and DLC1 and ECU (See page IN–28 ). Check ABS control relay (See step No. 2). Replace ABS control relay. Check for short in harness and connector between DLC1 and ABS control relay (See page IN–28). BR–134 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting terminals Te and E1 of the DLC1 or the DLC2 causes the ECU to display the diagnostic trouble code by flasing the ABS warning light. DIAGNOSTIC CHART Check voltage between terminals Tc and E1 of DLC2 or DLC 1. Check for open and short in harness and connec– tor between ABS ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN–28). Check and replace ABS ECU. If ABS warning light does not blink even after Tc and E1 are connected, the ECU may be defective.* Repair or replace harness or connector. *: Provided that the harness between terminal Tc of DLC2 or DLC1 and terminal Te of ECU is not open. BR–135 BRAKE SYSTEM WIRING DIAGRAM 1 MZ–FE: 5S–FE: – ANTI–LOCK BRAKE SYSTEM (ABS) BR–136 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals Te and E1 of DLC2 or DLC1. 1. Turn ignition switch ON. 2. Measure voltage between terminals Tc and E1 of DLC2 or DLC1. Voltage: 10–14 V If ABS warning light does not blink even after Tc and E1 are connected, the ECU may be defective. Check for open and short in harness and connector between ABS ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. BR–137 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the diagnostic trouble code check. Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check. DIAGNOSTIC CHART Check voltage between terminals Ts and E1 of DLC 1. If ABS warning light does not blink even after Ts and E 1 are connected, the ECU may be defective. Check for open and short in harness and connec– tor between ABS ECU and DLC1, DLC1 and body ground (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. WIRING DIAGRAM BR–138 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals and E1 of DLC1. 1. Turn ignition switch ON. 2. Measure voltage between terminals Ts and E1 of DLC 1. Voltage: 10–14 V If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective. Check for open and short in harness and connector between ABS ECU and DLC1, DLC1 and body ground (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. BR–139 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines. BR–140 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING (TMM Made Vehicle BOSCH ABS) HOW TO PROCEED WITH TROUBLESHOOTING Perform troubleshooting in accordance with the procedure on the following pages. (1) CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in as much detail as possible about the problem. (2) CHECK AND CLEAR THE DIAGNOSTIC TROUBLE CODES (PRECHECK) If the ABS warning light lights up, and the ABS does not operate, the ECU stores diagnostic trouble codes corresponding to the problem in memory. Before confirming the trouble, first check the diagnostic trouble codes to see if there are any malfunc– tion codes stored in memory. When there are malfunction codes, make a note of them, then clear them and proceed to ”3” Problem Symptom Confirmation”. (3) PROBLEM SYMPTOM CONFIRMATION, (4) SYMPTOM SIMULATION Confirm the problem symptoms. If the problem does not recur, simulate the problem by initially checking the circuits indicated by the diagnostic trouble code in step 2 , using ”Problem simulation method”. (5) DIAGNOSTIC TROUBLE CODE CHECK Check the diagnostic trouble codes. If a malfunction code is output, proceed to ”6” Diagnostic Trouble Code Chart”. If the normal code is output, proceed to ” 7” “Problem Symptoms Chart”. Be sure to proceed to ” 6 “Diagnostic Trouble Code Chart” after steps “2” and “3” are completed. If troubleshooting is attempted only by following the malfunction code stored in the memory, errors could be made in the diagnosis. (6) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is confirmed in the diagnostic trouble code check, proceed to the inspection procedure indicated by the matrix chart for each diagnostic trouble code. (7) PROBLEM SYMPTOMS CHART If the normal code is confirmed in the diagnostic trouble code check, perform inspection in accordance with the inspection order in the problem symptoms chart. (8) CIRCUIT INSPECTION Proceed with diagnosis of each circuit in accordance with the inspection order confirmed in 6 and 7 . Determine whether the cause of the problem is in the sensor, actuators, wire harness and con– nectars, or the ECU. (9) SENSOR CHECK Use the ABS warning light to check if each of the signals from the speed sensors are being input correctly to the ECU. Instructions for this check are given in the circuit inspection. (10) REPAIRS After the cause of the problem is located, perform repairs by following the inspection and replacement procedures in this manual. (11) CONFIRMATION TEST After completing repairs, confirm not only that the malfunction is eliminated, but also conduct a test drive to make sure the entire ABS system is operating correctly. BR–141 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Items inside E7 are titles of pages in this manu– al, with the page number in the bottom portion. See the pages for detailed explanations. Vehicle brought to workshop Customer Problem Analysis P. BR–142 Check and Clear Diagnostic Trouble Code (Precheck) P. BR–143–BR–144 . Symptom does not occur . Symptom Simulation P. IN–21 Problem Symptom Confirmation .Symptom.. occurs Normal code Diagnostic Trouble Code Check Problem Symptoms Chart P. BR–143 P. BR–14$ Diagnostic Trouble Code Chart P. BR–160
BR–184 Sensor Circuit Check Inspection P. BR–160–BR–184 Check for Fluid Leakage P. BR–185 Identification of Problem Repair Confirmation Test End Step 5. 9. : Diagnostic steps permitting the use of the TOYOTA hand–held. BR–142 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) CUSTOMER PROBLEM ANALYSIS CHECK SHEET BR–143 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSIS SYSTEM INDICATOR CHECK When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. HINT: If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit (See page BR– 177). DIAGNOSTIC TROUBLE CODE CHECK 1. Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 09843–18020 2. Turn the ignition switch to ON. 3. Read the diagnostic trouble code from the ABS warning light on the combination meter. HINT: If no code appears, inspect the diagnostic circuit or ABS warning light circuit (See page BR–180 or BR–177y. As an example, the blinking patterns for normal code and codes 11 and 21 are shown on the left. 4. Codes are explained in the code table on page BR–145. 5. After completing the check, disconnect terminals Tc and E1, and turn off the display. If 2 or more malfunctions are indicated at the same time, the lowest numbered diagnostic trouble code will be displayed first. BR–144 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Hook up the Toyota hand–held tester to the DLC2. 2. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the Toyota hand–held tester operator’s manual for further details. DIAGNOSTIC TROUBLE CODE CLEARANCE 1. Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 09843–18020 2. IG switch ON. 3. Clear the diagnostic trouble codes stored in ECU by de– pressing the brake pedal 8 or more times within 3 seconds. 4. Check that the warning light shows the normal code. 5. Remove the SST from the terminals of DLC2 or DLC1. HINT: Cancellation cannot be done by removing the battery cable or ECU–13 fuse. BR–145 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check, check the circuit listed for that code. Code ABS Warning Light Blinking Pattern Diagnosis Open or short circuit in ABS solenoid relay circuit Open or short circuit in ABS motor relay circuit Open or short circuit in 3–position solenoid circuit for right front wheel Open or short circuit in 3–position solenoid circuit for left front wheel Open or short circuit in 3–position solenoid circuit for rear wheels Right front wheel speed sensor signal malfunction Left front wheel speed sensor signal malfunction Right rear wheel speed sensor signal malfunction Left rear wheel speed sensor signal malfunction Open circuit in right front speed sensor circuit Open circuit in left front speed sensor circuit Faulty rear speed sensor rotor Open circuit in right rear speed sensor circuit Open circuit in left rear speed sensor circuit Low battery positive voltage Pump motor is locked Open in pump motor circuit in actuator Malfunction in ECU BR–146 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) SPEED SENSOR SIGNAL CHECK 1. When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. 2. Turn the ignition switch to OFF. 3. Using SST, connect terminals Ts and El of DLC1. SST 09843–18020 4. Start the engine. 5. Check that the ABS warning light blinks HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit (See page BR–177j. 6. Drive vehicle straight forward. HINT: • Drive vehicle at 45–55 km/h (28–34 mph) for several seconds. • If the brake is applied during the check, the check routine must be started again. 7. Stop the vehicle. 8. Turn the ignition switch to OFF. 9. Disconnect terminals Ts and E1, and connect Te and E1. 10. Turn the ignition switch to ON. 11. Read the number of blinks of the ABS warning light. HINT: See the list of diagnostic trouble codes shown on the next page. If every sensor is normal, a normal code is output (A cycle of 0.25 sec. ON and 0.25 sec. OFF is repeated). If 2 or more malfunctions are indicated at the same time, the lowest numbered code will be displayed first. 12. After performing the check, disconnect terminals Tc and E1 of DLC1, and ignition switch turned off. BR–147 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Perform steps 1.
7. on the previous page. 2. Hook up the Toyota hand–held tester to the DLC2. 3. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the Toyota hand–held tester operator’s manual for further details. Diagnostic Trouble Code of Speed Sensor Check Function Code No. Trouble Area Diagnosis Low output voltage of right front speed sensor • • Right front speed sensor Sensor installation Low output voltage of left front speed sensor • • Left front speed sensor Sensor installation Low output voltage of right rear speed sensor • • Right rear speed sensor Sensor installation Low output voltage of left rear speed sensor • • Left rear speed sensor Sensor installation Abnormal change in output voltage of right front speed sensor • Right front speed sensor rotor Abnormal change in output voltage of left front speed sensor • Left front speed sensor rotor Abnormal change in output voltage of right rear speed sensor • Right rear speed sensor rotor Abnormal change in output voltage of left rear speed sensor • Left rear speed sensor rotor BR–148 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) PROBLEM SYMPTOMS CHART If a normal code is displayed during the diagnostic trouble code check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. Inspection Circuit Symptoms ABS does not operate. ABS does not operate efficiently. Only when 1.
4. are all normal and the problem is still occurring, replace the ABS ECU. 1. Check the diagnostic trouble code, reconfirming that the normal code is output. 2. IG power source circuit. 3. Speed sensor circuit. 4. Check the hydraulic circuit for leakage. Only when 1.
4. are all normal and the problem is still occurring, replace the ABS ECU. 1. Check the diagnostic trouble code, reconfirming that the normal code is output. 2. Speed sensor circuit. 3. Stop light switch circuit. 4. Check the hydraulic circuit for leakage. ABS warning light abnormal. 1. ABS warning light circuit. 2. ABS ECU. Diagnostic trouble code check cannot be performed. Only when 1. and 2. are all normal and the problem is still occurring, replace the ABS ECU. 1. ABS warning light circuit. 2. Tc terminal circuit. Speed sensor signal check cannot be performed. See page BR–143 BR–170 BR–166 BR–185 BR–143 BR–166 BR–175 BR–185 BR–177 BR–177 BR–180 BR–183 1. Ts terminal circuit. 2. ABS ECU. BR–149 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) LOCATION OF CONNECTORS Location of Connectors in Engine Compartment 1M2–FE Engine: BR–150 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–151 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in Engine Compartment 5S–FE Engine: BR–152 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–153 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in instrument Panel BR–154 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–155 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–156 BRAKE SYSTEM – J/B No. 1 ANTI–LOCK BRAKE SYSTEM (ABS) BR–157 BRAKE SYSTEM Location of Connectors in Body Sedan: Coupe: – ANTI–LOCK BRAKE SYSTEM (ABS) BR–158 BRAKE SYSTEM Wagon: – ANTI–LOCK BRAKE SYSTEM (ABS) BR–159 BRAKE SYSTEM –MEMO– – ANTI–LOCK BRAKE SYSTEM (ABS) BR–160 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) CIRCUIT INSPECTION DTC 11,13 ABS Solenoid and Motor Relay Circuit CIRCUIT DESCRIPTION The solenoid relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. The motor relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches the motor relay ON and operates the ABS pump motor. DTC No. Diagnostic Trouble Code Detecting Condition Trouble area (1) 5V is applied to the solenoid voltage monitor terminal (AST) for 30 sec. or more, with the IG switch ON and the warning light on. (2) 5V is applied to the solenoid voltage monitor terminal (AST) for 0.02 sec. or more, after the warning light goes off. • • Open or short in ABS solenoid relay circuit. ECU. (1) The motor voltage monitor terminal (MT) is ON for 5 sec. or more, with the motor relay operation signal OFF. (2) The motor voltage monitor terminal (MT) is OFF for 0.04 sec. with the motor relay opera– tion signal ON. • • • Pump motor. Open in ABS motor relay circuit. ECU. Fail safe function: If trouble occurs in the control (solenoid) relay circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. DIAGNOSTIC CHART Check voltage of ABS ECU connector. Check and repair harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. HINT: When DTC13 is output, check that the pump motor ground wire is installed correctly. BR–161 BRAKE SYSTEM WIRING DIAGRAM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–162 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals connector. 1 and 4 of ABS ECU Disconnect the ABS ECU connector. Measure voltage between terminals A5 1 and A5 4 of ABS ECU harness side connector. Voltage: 10–14 V Check and repair harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–163 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 21, 22, 23 ABS Actuator Solenoid Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders, thus controlling the braking force. DTC No. Diagnostic Trouble Code Detecting Condition Trouble area (1) OV is applied to terminal SFR for 0.035 sec. while battery voltage is applied to the sole– noid voltage monitor terminal (AST) and the ECM power transistor is OFF. (2) Battery voltage is applied to terminal SFR for 0.035 sec. while battery voltage is applied to the solenoid voltage monitor terminal (AST) and the ECM power transistor is ON. • • • ABS actuator (solenoid valve). Open or short in right front solenoid circuit. ECU. (1) OV is applied to terminal SFL for 0.035 sec. while battery voltage is applied to the sole– noid voltage monitor terminal (AST)and the ECM power transistor is OFF. (2) Battery voltage is applied to terminal SFL for 0.035 sec. while battery voltage is applied to the solenoid voltage monitor terminal (AST) and the ECM power–transistor is ON. • • • ABS actuator (solenoid valve). Open or short in left front solenoid circuit. ECU. (1) OV is applied to terminal SRA for 0.035 sec. while battery voltage is applied to the sole– noid voltage monitor terminal (AST) and the ECM power transistor is OFF. (2) Battery voltage is applied to terminal SRA for 0.035 sec. while battery voltage is applied to the solenoid voltage monitor terminal (AST) and the ECM power transistor is ON. • • • ABS actuator (solenoid valve). Open or short in rear solenoid circuit. ECU. Fail safe function; If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the solenoid relay and prohibits ABS control. Check ABS actuator solenoid. Replace ABS actuator. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–164 BRAKE SYSTEM WIRING DIAGRAM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–165 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check ABS actuator solenoid. Remove the ABS ECU cover and disconnect 6–pin connector. Check continuity between terminals 1 and 2, 3 and 4, 5 and6. Continuity HINT: Resistance of each solenoid coil is 1.1
. Replace ABS actuator. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–166 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 31,32,33,34,35, 36, 38, 39 Speed Sensor Circuit CIRCUIT DESCRIPTION The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system. The front and rear rotors each have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. DTC No. 31,32, 33,34 Diagnostic Trouble Code Detecting Condition (1) No pulse is input when the vehicle speed reaches 12 km/h (7 mph). (2) No pulse is input when the vehicle speed reaches 20 km/h (12 mph). (3) When the vehicle speed is 10 km/h (7 mph) or above, a pulse is not input for at least 20 sec. Trouble area • • • • • • 35,36, 38,39 The hardware detects a constant open is each sensor circuit. • • Right front, left front, right rear and left rear speed sensor. Open in each speed sensor circuit. Sensor installation Sensor rotor ECU. Right front, left front, right rear and left rear speed sensor. Open in each speed sensor circuit. ECU. HINT: DTC Nos. 31 and 35 are for the right front speed sensor. DTC Nos. 32 and 36 are for the left front speed sensor. DTC Nos. 33 and 38 are for the right rear speed sensor DTC Nos. 34 and 39 are for the left rear speed sensor. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. BR–167 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC CHART Check speed sensor. Replace speed sensor. Check for open and short in harness and con– nector between each speed sensor and ECU. Repair or replace harness or connector. Check sensor rotor and sensor installation. Replace speed sensor or rotor. Check and replace ABS ECU. WIRING DIAGRAM BR–168 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check speed sensor. Front 1. Remove front fender liner. 2. Disconnect speed sensor connector. Measure resistance between terminals 1 and 2 of speed sensor connector. Resistance: 0.6–1.8 k
Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. Resistance: 1 MO or higher Rear 1. Remove the seat cushion (and side seat back). 2. Disconnect speed sensor connector. Measure resistance between terminals 1 and 2 of speed sensor connector. Resistance: 0.6–1.8 tc
Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. Resistance: 1 M
or higher Replace speed sensor. Check for open and short in harness and connector between each speed sensor and ECU (See page IN–28). Repair or replace harness or connector. BR–169 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check sensor rotor and sensor installation. Front Remove front drive shaft (See SA section). Check sensor rotor serrations. No scratches or missing teeth. Check the front speed sensor installation The installation bolt is tightened properly. Rear Remove the axle hub (See SA section). Check the sensor rotor serrations. No scratches or missing teeth. Check the speed sensor installation The installation bolt is tightened properly and there is no clearance between the sensor and rear axle carrier. Replace speed speed or rotor. Check and replace ABS ECU. BR–170 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 41 +BS Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the CPU, and the actuators. DTC No. Diagnostic Trouble Code Detecting Condition (1) Voltage of 5V or more, or 9.4V or less, is applied for at least 60 sec. to terminal +BS before the ABS primary check and ABS operation. (2) Voltage of 5V or more, or 9.4V or less, is applied to terminal +BS for 0.2 sec. or more, after the ABS primary check and before ABS operation. (3) During ABS operation, voltage of 5V or more, or 8.8V or less, is applied to terminal +BS for 0.2 sec. or more. Trouble area • • • • Battery. IC regulator. Open or short in power source circuit. ECU. Fail safe function: If trouble occurs in the power source circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. If the voltage applied to terminal +BS becomes 9.9V or less, the warning light goes off and ABS control becomes possible. DIAGNOSTIC CHART Check battery positive voltage. Check and repair the charging system. Check voltage between terminals +BS and GND of ABS ECU connector. Check and replace ABS ECU. Check continuity between terminals GND of ABS ECU connector and body ground. Check ECU–IG fuse. Check for open in harness and connector between ABS ECU and battery. Repair or replace harness or connector. Check for short in all the harness and components connected to ECU–IG fuse (See attached wiring diagram). BR–171 BRAKE SYSTEM WIRING DIAGRAM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–172 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check battery positive voltage. Voltage: 10–14 V Check and repair the charging system. Check voltage between terminals +BS and GND of ABS ECU connector. Disconnect ABS ECU connector. 1. Turn ignition switch ON. 2. Measure voltage between terminals IG1 and GND of ABS ECU connector. Voltage: 10–14 V Check and replace ABS ECU. Check continuity between terminal GND of ABS ECU connector and body ground. Measure resistance between terminal GND of ABS ECU connector and body ground. Resistance: 1
or less Repair or replace harness or connector. BR–173 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check ECU–IG fuse. Remove ECU–IG fuse from J/B No. 1. Check continuity of ECU–IG fuse. Continuity Check for short in. a1I the harness and components connected to ECU–IG fuse (See attached wiring diagram). Check for open in harness and connector between ABS ECU and battery (See page IN–28). BR–174 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION DTC No. Diagnostic Trouble Code Detecting Condition Pump motor is not operating normally during initial check. Trouble area • ABS pump motor. Fail safe function: If trouble occurs in the ABS pump motor, the ECU cuts off current to the solenoid relay and prohibits ABS control. DIAGNOSTIC CHART Check that the pump motor ground wire is installed correctly. If it is OK, replace the ABS actuator assembly. BR–175 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Stop Light Switch Circuit CIRCUIT DESCRIPTION This stop light switch senses whether the brake pedal is depressed or released, and sends the signal to the ECU. DIAGNOSTIC CHART Check operation of stop light. Repair stop light circuit (See page BE– 65). Check voltage of terminal STP. Proceed to next circuit inspection shown on problem symptoms chart (See page BR–148y. Check for open in harness and connector be– tween ABS ECU and stop light switch (See page IN–27). Repair–or replace harness or connector. Check and replace ABS ECU. WIRING DIAGRAM BR–176 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check operation of stop light. Check that stop light lights up when brake pedal is depressed and turns off when brake pedal is released. Repair stop light circuit (See page BE–65). Check voltage between terminal STP of ABS ECU connector and body ground. Disconnect ABS ECU connector. Measure voltage between terminal STP and body ground. Voltage: 8–14 V Proceed to next circuit inspection shown on problem symptoms chart (See page BR–148 ). Check for open in harness and connector between ABS ECU and stop light switch (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. BR–177 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a diagnostic trouble code in memory. Connect terminals Tc and E1 of the DLC1 or DLC2 to make the ABS warning light to blink and output the diagnostic trouble code. DIAGNOSTIC CHART Perform troubleshooting in accordance with the chart below for each trouble symptom. ABS warning light does not light up Go to step ABS warning light remains on Go to step WIRING DIAGRAM BR–178 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS warning light does not light up. Repair or replace ABS warning light bulb or circuit. Check ABS warning light. Check for–open in harness and connector–be– tween GAUGE fuse and ECU. ABS warning light remains on. Is diagnostic trouble code output? Does ABS warning light go off if short pin is removed? YES Check for short in harness and connector be– tween DLC1 and ECU terminal WB. YES Repair circuit indicated by the code output. Check for short in harness and connec– tor between warning light and DLC1, DLC2 and ECU terminal WA. BR–179 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check ABS warning light. See Combination Meter–Troubleshooting on page BE–1 18. Replace bulb or combination meter assembly. Check for open in harness and connector between GAUGE fuse and ECU (See page IN–27). Is diagnostic trouble code output? Perform diagnostic trouble code check on page BR–143. YES Repair circuit indicated by the code output. Does ABS warning light go off if short pin is removed? YES Check for short in harness and connector between warning light and DLC1, DLC2 and ECU terminal WA (See page IN–28). Check for short in harness and connector between DLC1 and ECU terminal WB (See page IN–27). BR–180 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Terminal Circuit CIRCUIT DESCRIPTION Connecting terminals Te and E1 of the DLC1 or the DLC2 causes the ECU to display the diagnostic trouble code by flasing the ABS warning light. DIAGNOSTIC CHART Check voltage between terminals Tc and El of DLC2 or DLC 1. If ABS warning light does not blink even after Tc and E1 are connected, the ECU may be defective.* Check for open and short in harness and connec– tor between ABS ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN–28). Repair or replace harness or connector. Check and replace A6S ECU. *: Provided that the harness between terminal Tc of DLC2 or DLC1 and terminal Tc of ECU is not open. BR–181 BRAKE SYSTEM WIRING DIAGRAM 1 M^–FE: 5S–FE: – ANTI–LOCK BRAKE SYSTEM (ABS) BR–182 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals Te and E1 of DLC2 or DLC1. 1. Turn ignition switch ON. 2. Measure voltage between terminals Tc and E1 of DLC2 or DLC1. Voltage: 10–14 V If ABS warning light does not blink even after Tc and E 1 are connected, the ECU may be defective. Check for open and short in harness and connector between ABS ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. BR–183 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which can not be detected with the diagnostic trouble code check. Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check. DIAGNOSTIC CHART Check voltage between terminals Ts and E1 of DLC1. If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective. Check for open and short in harness and connec– tor between ABS ECU and DLC1, DLC1 and body ground (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. WIRING DIAGRAM BR–184 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals¿¿and E1 of DLC1. 1. Turn ignition switch ON. 2. Measure voltage between terminals Ts and E1 of DLC 1. Voltage: 10–14 V If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective. Check for open and short in harness and connector between ABS ECU and DLC1, DLC1 and body ground (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. BR–185 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines. BR–186 BRAKE SYSTEM – BRAKE BOOSTER BRAKE BOOSTER BRAKE BOOSTER REMOVAL 1. REMOVE MASTER CYLINDER (See page BR–12) 2. PUSH DOWN CHARCOAL CANISTER Loosen the clamp screw and push the charcoal canis– ter down slightly. BR–187 BRAKE SYSTEM – BRAKE BOOSTER 3. DISCONNECT VACUUM HOSE FROM BRAKE BOO – STER 4. REMOVE PEDAL RETURN SPRING 5. REMOVE CLIP AND CLEVIS PIN 6. REMOVE BRAKE BOOSTER, GASKET AND CLEVIS (a) Remove the 4 nuts and clevis. (b) Pull out the brake booster and gasket. BRAKE BOOSTER INSTALLATION 1. INSTALL BRAKE BOOSTER (a) Install the booster and a new gasket. (b) Install the clevis to the operating rod. (c) Install and torque the booster installation nuts. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) (d) Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin. (e) Install the pedal return spring. 2. ADJUST LENGTH OF BOOSTER PUSH ROD (a) Install the gasket on the master cylinder. (b) Set the SST on the gasket, and lower the pin until its tip slightly touches the piston. (c) Turn the SST upside down, and set it on the booster. (d) Measure the clearance between the booster push rod and pin head (SST). Clearance: 0 mm (0 in.) (e) Adjust the booster push rod length until the push rod slightly touches the pin head. 3. INSTALL CHARCOAL CANISTER TO ORIGINAL PO– SITION 4. INSTALL MASTER CYLINDER 5. CONNECT VACUUM HOSE TO BRAKE BOOSTER 6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 7. CHECK FOR LEAKS BR–188 BRAKE SYSTEM – BRAKE BOOSTER 8. CHECK AND ADJUST BRAKE PEDAL (See page BR–8) Check and adjust the brake pedal, then tighten the clevis lock nut. Torque: 25 N–m (260 kgf–cm, 19 ft–lbf) 9. PERFORM OPERATIONAL CHECK (See page BR–9) BR–189 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) FRONT BRAKE (Single–Piston Type) COMPONENTS BRAKE PADS REPLACEMENT 1. REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with hub nuts. BR–190 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspec– tion hole and replace the pads if it is not within the specification. Minimum thickness: 1.0 mm (0.039 in.) 3. LIFT UP CALIPER (a) Hold the sliding pin on the bottom and loosen the installation bolt. (b) Remove the installation bolt. (c) Lift up the caliper and suspend the caliper with string. HINT: Do not disconnect the flexible hose from the caliper. 4. REMOVE FOLLOWING PARTS: (a) 2 anti–squeal springs (b) 2 brake pads (c) 4 anti–squeal shims (d) 1 MZ–FE engine: Pad wear indicator (e) 4 pad support plates 5. CHECK DISC THICKNESS AND RUNOUT (See page BR–26) BR–191 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 6. INSTALL PAD SUPPORT PLATES Install the 4 pad support plates. 7. INSTALL NEW PADS (a) 1 MZ–FE engine: Install a pad wear indicator plate on the inside pad. (b) Apply disc brake grease to both sides of the inner anti –squeal shim. (c) Install the 2 anti–squeal shims on each pad. (d) install inside pad with the pad wear indicator plate facing upward. (e) Install outside pad. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. (f) Install the 2 anti–squeal springs. 8. INSTALL CALIPER (a) Draw out a small amount of brake fluid from the reservoir. (b) Press in the piston with water pump pliers or similar implement. HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. BR–192 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) (c) Install the caliper. (d) Hold the sliding pin and torque the installation bolt. Torque: 34 N–m (350 kgf–cm, 25 ft–lbf) 9. INSTALL FRONT WHEEL 10. CHECK THAT FLUID LEVEL IS AT MAX LINE CALIPER REMOVAL 1. DISCONNECT FLEXIBLE HOSE (a) Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. (b) Use a container to catch the brake fluid as it drains out. 2. REMOVE CALIPER (a) Hold the sliding pin and loosen the 2 installation bolts. (b) Remove the 2 installation bolts. (c) Remove the caliper from the torque plate. 3. REMOVE 2 BRAKE PADS Remove the inside and outside pads. CALIPER DISASSEMBLY 1. REMOVE CYLINDER BOOT SET RING AND CYLIN– DER BOOT Using a screwdriver, remove the cylinder boot set ring and cylinder boot from the caliper. BR–193 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 2. REMOVE PISTON (a) Place a piece of cloth or similar article between the piston and the caliper. (b) Use compressed air to remove the piston from the cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed sir. 3. REMOVE PISTON SEAL Using a screwdriver, remove the piston seal from the cylinder. 4. REMOVE SLIDING PINS AND DUST BOOTS (a) Remove the 2 sliding pins from the torque plate. (b) Using a screwdriver and hammer, tap out the 2 dust boots. BR–194 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) FRONT BRAKE COMPONENTS INSPECTION AND REPAIR 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 5S–FE engine 12.0 mm (0.472 In.) 1 MZ–FE engine 11.0 mm (0.433 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad’s thickness is at the mini– mum thickness or less, or if the pad has excessively uneven wear. 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 28.0 mm (1.102 in.) Minimum thickness: 26.0 mm (1.024 in.) Replace the disc if the disc’s thickness is at the mini– mum thickness or less. Replace the disc or grind it on a lathe if it is badly scored or worn unevenly. 3. MEASURE DISC RUNOUT Measure disc runout 10 mm (0.39 in.) from the outer edge of the disc. Maximum disc runout: 0.05 mm (0.0020 in.) If runout is greater than maximum, attempt to adjust to below this maximum figure. HINT: Before measuring the runout, confirm that the front bearing play is within specification. 4. IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the torque plate from the knuckle. (b) Remove the hub nuts and the disc. Reinstall the disc 1/5 of a turn round from its original position on the hub. Install and torque the hub nuts. Torque: 103 N–m (1,050 kgf–cm, 76 ft–lbf) Remeasure the disc runout. Make a note of the runout and the disc’s position on the hub. BR–195 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) (c) Repeat (b) until the disc has been installed on the 3 remaining hub positions. (d) If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020in.), install the disc in that position. (e) If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3. (f) Install the torque plate and torque the mounting bolts. Torque: 107 N–m (1,090 kgf–cm, 79 ft–lbf) CALIPER ASSEMBLY 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO PARTS INDICATED WITH ARROWS 2. INSTALL DUST BOOTS AND SLIDING PINS (a) Using a 19 mm socket wrench and hammer, tap in 2 new dust boots into the torque plate. (b) Confirm that the metal plate portion of the dust boot fits snugly in the torque plate. (c). Insert 2 sliding pins into the torque plate. NOTICE: Insert the sliding pin with sliding bushing into the bottom side. 3. INSTALL PISTON SEAL AND PISTON IN CYLINDER BR–196 BRAKE SYSTEM – FRONT BRAKE(Single–Piston Type) 4. INSTALL CYLINDER BOOT AND CYLINDER BOOT SET RING CALIPER INSTALLATION 1. INSTALL 2 BRAKE PADS Install the inside and outside pads. 2. INSTALL CALIPER (a) Temporarily install the caliper on the torque plate with the 2 installation bolts. (b) Hold the sliding pin and torque the installation bolt. Torque: 34 N–m (350 kgf–cm, 25 ft–lbf) 3. CONNECT FLEXIBLE HOSE Install the flexible hose on the caliper with 2 new gaskets. Torque: 29 N–m (300 kgf–cm, 21 ft–lbf) HINT: Install the flexible hose lock securely in the lock hole in the caliper. 4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 5. CHECK FOR LEAKS BR–197 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) FRONT BRAKE (2–Piston Type) COMPONENTS BRAKE PADS REPLACEMENT 1. REMOVE FRONT WHEEL Remove the wheel and temporarily fasten the disc with the hub nuts. BR–198 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspec– tion hole and replace the pads if it is not within the specification. Minimum thickness: 1.0 mm (0.039 in.) 3. LIFT UP CALIPER (a) Hold the sliding pin on the bottom and loosen the installation bolt. (b) Remove the installation bolt. (c) Lift up and suspend the caliper. HINT: Do not disconnect the flexible hose from the brake caliper. 4. REMOVE FOLLOWING PARTS: (a) 2 anti–squeal springs (b) 2 brake pads (c) 4 anti–squeal shims (d) 4 pad support plates (e) Pad wear indicator 5. CHECK DISC THICKNESS AND RUNOUT (See page BR–33) 6. INSTALL PAD SUPPORT PLATES Install the 4 pad support plates. BR–199 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 7. INSTALL NEW PADS (a) Install the pad wear indicator plate on the pad. (b) Apply disc brake grease to both sides of the inner anti–squeal shim. (c) Install the 2 anti–squeal shims on each pad. (d) Install the inner pad with the pad wear indicator plates facing upward. (e) Install the outer pad. NOTICE: There should be no oil or grease adhering to the friction surface’s of the pads or the disc. (f) Install the 2 anti–squeal springs. 8. INSTALL CALIPER (a) Draw out a small amount of brake fluid from the reservoir. (b) Press in the piston with a hammer handle or similar implement. HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. (c) Install the caliper. (d) Hold the sliding pin and torque the installation bolt. Torque: 34 N .m (350 kgf–cm, 25 ft–lbf) 9. INSTALL FRONT WHEEL 10. CHECK THAT FLUID LEVEL IS AT MAX LINE CALIPER REMOVAL 1. DISCONNECT FLEXIBLE HOSE (a) Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. (b) Use a container to catch the brake fluid as it drains out. BR–200 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. REMOVE CALIPER (a) Hold the sliding pin and loosen the 2 installation bolts. (b) Remove the 2 installation bolts. (c) Remove the caliper from the torque plate. 3. REMOVE FOLLOWING PARTS: (a) 2 anti–squeal springs (b) 2 brake pads with anti–squeal shims (c) 4 pad support plates CALIPER DISASSEMBLY 1. REMOVE CYLINDER BOOT SET RINGS AND CYLIN– DER BOOTS Using a screwdriver, remove the 2 cylinder boot set rings and cylinder boots from the caliper. 2. REMOVE PISTONS (a) Place a piece of cloth or similar article between the piston and caliper. (b) Use compressed air to remove the pistons from the cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed air. 3. REMOVE PISTON SEALS Using a screwdriver, remove the 2 piston seals from the cylinder. BR–201 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 4. REMOVE SLIDING PINS AND DUST BOOTS (a) Remove the 2 sliding pins from the torque plate. (b) Using a screwdriver and hammer, tap out the 2 dust boots. FRONT BRAKE COMPONENTS INSPECTION AND REPAIR 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 11.0 mm (0.433 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad’s thickness is at the mini– mum thickness or less, or if the pad has excessively uneven wear. 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 28 mm (1.102 in.) Minimum thickness: 26 mm (1.024 in.) Replace the disc if the disc’s thickness is at the mini– mum thickness or less. Replace the disc or grind it on a lathe if it is badly scored or worn unevenly. 3. MEASURE DISC RUNOUT Measure disc runout 10 mm (0.39 in.) from the outer edge of the disc. Maximum disc runout: 0.05 mm (0.0020 in.) If runout is greater than maximum, attempt to adjust to below this maximum figure. BR–202 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) HINT: Before measuring the runout, confirm that the front bearing play is within specification. 4. IF NECESSARY, ADJUST DISC RUNOUT (a) Remove the torque plate from the knuckle. (b) Remove the hub nuts and the disc. Reinstall the disc 1/5 of a turn round from its original position on the hub. Install and torque the hub nuts. Torque: 103 N–m (1,050¿¿f¿cm, 76 ft–lbf) Remeasure the disc runout. Make a note of the runout and disc’s position on the hub. (c) Repeat (b) until the disc has been installed on the 3 remaining hub positions. (d) If the minimum runout recorded in (b) and (c) is less than 0.05 mm (0.0020 in.), install the disc in that position. (e) If the minimum runout recorded in (b) and (c) is greater than 0.05 mm (0.0020 in.), replace the disc and repeat step 3. (f) Install the torque plate and torque the mounting bolts. Torque: 107 N–m (1,090 kgf–cm, 79 ft–lbf) CALIPER ASSEMBLY 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO PARTS INDICATED WITH ARROWS BR–203 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. INSTALL DUST BOOTS AND SLIDING PINS (a) Using a 19 mm socket and a hammer, tap in 2 new dust boots into the torque plate. (b) Confirm that the metal plate portion of the dust boot fits snugly in the torque plate. (c) Insert 2 sliding pins into the torque plate. NOTICE: Insert the sliding pin with sliding bushing into the bottom side 3. INSTALL PISTON SEALS AND PISTONS IN CYLIN – DER 4. INSTALL CYLINDER BOOTS AND CYLINDER BOOT SET RINGS CALIPER INSTALLATION 1. INSTALL FOLLOWING PARTS: (a) 4 pad support plates (b) 2 brake pads with anti–squeal shims (c) 2 anti–squeal springs BR–204 BRAKE SYSTEM – FRONT BRAKE(2–Piston Type) 2. INSTALL CALIPER (a) Temporarily install the caliper on the torque plate with the 2 installation bolts. (b) Hold the sliding pin and torque the installation bolt. Torque: 34 N–m (350 kgf–cm, 26 ft–lbf) 3. CONNECT FLEXIBLE HOSE Install the flexible hose on the brake caliper with 2 new gaskets. Torque: 29 N–m (300 kgf–cm, 21 ft–lbf) HINT: Insert the flexible hose lock securely in the lock hole in the brake caliper. 4. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 5. CHECK FOR LEAKS BR–205 BRAKE SYSTEM – REAR BRAKE(Drum Brake) REAR BRAKE (Drum Brake) COMPONENTS REAR DRUM BRAKE REMOVAL 1. INSPECT SHOE LINING THICKNESS Remove the inspection hole plug, and check the shoe lining thickness through the hole. If less than minimum, replace the shoes. Minimum thickness: 1.0 mm (0.039 in.) 2. REMOVE REAR WHEEL 3. REMOVE BRAKE DRUM HINT: If the brake drum cannot be removed easily, perform the following steps. (a) Insert a bent wire or an equivalent through the hole in the brake drum, and hold the automatic adjusting lever away from the adjuster. (b) Using a screwdriver, reduce the brake shoe adjust– ment by turning the adjuster. BR–206 BRAKE SYSTEM – REAR BRAKE(Drum Brake) 4. REMOVE FRONT SHOE (a) Using SST, disconnect the return spring. SST 09703–30010 (b) Using SST, remove the shoe hold–down spring, cups and pin. SST 09718–00010 (c) Disconnect the anchor spring from the front shoe and remove the front shoe. (d) Remove the anchor spring from the rear shoe. 5. REMOVE REAR SHOE (a) Using SST, remove the shoe hold–down spring, cups and pin. SST 09718–00010 (b) Using a screwdriver, disconnect the parking brake cable from the anchor plate. (c) Using pliers, disconnect the parking brake cable from the lever and remove the rear shoe together with the adjuster. 6. REMOVE ADJUSTER FROM REAR SHOE (a) Remove the adjusting lever spring. (b) Remove the adjuster together with the return spring. 7. DISCONNECT BRAKE LINE FROM WHEEL CYLIN – DER Using SST, disconnect the brake line. Use a container to catch the brake fluid. SST 09751–36011 BR–207 BRAKE SYSTEM – REAR BRAKE(Drum Brake) 8. REMOVE WHEEL CYLINDER Remove the 2 bolts and the wheel cylinder. 9. IF NECESSARY, DISASSEMBLE WHEEL CYLINDER Remove the following parts from the wheel cylinder. • 2 boots • 2 pistons • 2 piston cups • Spring REAR DRUM BRAKE COMPONENTS INSPECTION AND REPAIR 1. INSPECT DISASSEMBLED PARTS Inspect the disassembled parts for wear, rust or damage. 2. MEASURE BRAKE SHOE LINING THICKNESS Standard thickness: 5.0 mm (0.197 in.) Minimum thickness: 1.0 mm (0.039 in.) If the shoe lining is less than minimum or shows signs of uneven wear, replace the brake shoes. HINT: If any of the brake shoes have to be replaced, replace all of the rear shoes in order to maintain even braking. 3. MEASURE BRAKE DRUM INSIDE DIAMETER Standard inside diameter: 228.6 mm (9.000 in.) Maximum inside diameter: 230.6 mm (9.079 in.) If the drum is scored or worn, the brake drum may be lathed to the maximum inside diameter. BR–208 • BRAKE SYSTEM – REAR BRAKE(Drum Brake) 4. INSPECT REAR BRAKE LINING AND DRUM FOR PROPER CONTACT If the contact between the brake lining and drum is improper, repair the lining with a brake shoe grinder, or replace the brake shoe assembly. REAR DRUM BRAKE INSTALLATION HINT: Assemble the parts in the correct direction as shown. 1. ASSEMBLE WHEEL CYLINDER (a) Apply lithium soap base glycol grease to the cups and pistons as shown. (b) Assemble the wheel cylinder. HINT: Install in proper direction only. • Spring • 2 cups • 2 pistons • 2 boots 2. INSTALL WHEEL CYLINDER Install the wheel cylinder on the backing plate with the 2 bolts. Torque: 10 N–m (100 kgf–cm, 7 ft–lbf) BR–209 BRAKE SYSTEM – REAR BRAKE(Drum Brake) 3. CONNECT BRAKE LINE TO WHEEL CYLINDER Using SST, connect the brake line. SST 09751–36011 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 4. APPLY HIGH TEMPERATURE GREASE TO BACK – ING PLATE AND ADJUSTER (a) Apply high temperature grease to the brake shoe contact surfaces. (b) Apply high temperature grease to the adjuster bolt threads and ends. 5. INSTALL ADJUSTER ONTO REAR SHOE Set the adjuster and return spring and install the adjusting lever spring. 6. INSTALL REAR SHOE (a) Using pliers, connect the parking brake cable to the lever. (b) Pass the parking brake cable through the notch in the anchor plate. (c) Set the rear shoe in place with the end of the shoe inserted in the wheel cylinder and the other end in the anchor plate. BR–210 BRAKE SYSTEM – REAR BRAKE(Drum Brake) (d) Using SST, install the shoe hold–down spring, cups and pin. SST 09718–00010 NOTICE: Do not allow oil or grease to get on the rubbing face. 7. INSTALL FRONT SHOE (a) Install the anchor spring between the front and rear shoes. (b) Set the front shoe in place with the end of the shoe inserted in the wheel cylinder and the adjuster in place. (c) Using SST, install the shoe hold–down spring, cups and pin. SST 09 718–00010 NOTICE: Do not allow oil or grease to get on the rubbing face. (d) Using SST, connect the return spring. SST 09703–30010 8. CHECK OPERATION OF AUTOMATIC ADJUSTING MECHANISM (a) Move the parking brake lever of the rear shoe back and forth. Check that the adjuster turns. If the adjuster does not turn, check for incorrect installation of the rear brakes. (b) Adjust the adjuster length to the shortest possible amount. BR–211 BRAKE SYSTEM – REAR BRAKE(Drum Brake) (c) Align the adjusting hole on the brake drum and largest hole on the axle carrier, install the brake drum. (d) Pull the parking brake lever all the way up until a clicking sound can no longer be heard. 9. CHECK CLEARANCE BETWEEN BRAKE SHOES AND DRUM (a) Remove the brake drum. (b) Measure the brake drum inside diameter and diameter of the brake shoes. Check that the difference between the diameters is the correct shoe clearance. Shoe clearance: 0.6 mm (0.024 in.) If incorrect, check the parking brake system. 10. INSTALL BRAKE DRUM 11. INSTALL REAR WHEEL 12. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 13. CHECK FOR LEAKS BR–212 BRAKE SYSTEM – REAR BRAKE(Disc Brake) REAR BRAKE (Disc Brake) COMPONENTS BR–213 BRAKE SYSTEM – REAR BRAKE(Disc Brake) BRAKE PADS REPLACEMENT 1. REMOVE REAR WHEEL Remove the wheel and temporarily fasten the disc with the hub nuts. 2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspec– tion hole and replace pads if not within specification. Minimum thickness: 1.0 mm (0.039 in.) 3. LIFT UP CALIPER (a) Remove the flexible hose bracket. (b) Remove the installation bolt from the torque plate. (c) Lift up the caliper and suspend the caliper with string. HINT: Do not disconnect the flexible hose from the caliper. BR–214 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 4. REMOVE FOLLOWING PARTS: (a) 2 brake pads (b) 4 anti–squeal shims (c) 4 pad support plates 5. CHECK DISC THICKNESS AND RUNOUT (See page BR–50) 6. INSTALL PAD SUPPORT PLATES Install the 4 pad support plates. 7. INSTALL NEW PADS (a) Apply disc brake grease to both side of the inner anti –squeal shims. (b) Install the 2 anti–squeal shims on each pad. (c) Install 2 pads with the pad wear indicator plates facing up ward. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. 6. INSTALL CALIPER (a) Draw out a small amount of brake fluid from the reservoir. (b) Press in the piston with water pump pliers or similar implement. HINT: If the piston is difficult to push in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. BR–215 BRAKE SYSTEM – REAR BRAKE(Disc Brake) (c) Install the caliper and torque the installation bolt. Torque: 20 N–m (200 kgf–cm, 14 ft–lbf) (d) Install the flexible hose bracket. Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) 9. INSTALL REAR WHEEL 14. CHECK THAT FLUID LEVEL IS AT MAX LINE CALIPER REMOVAL 1. DISCONNECT FLEXIBLE HOSE (a) Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. (b) Use a container to catch the brake fluid as it drains out. 2. REMOVE CALIPER (a) Remove the installation bolt. (b) Remove the caliper from the torque plate. BR–216 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 3. REMOVE 2 PADS Remove the inside and outside pads. 4. REMOVE MAIN PIN Loosen the. main pin installation bolt and remove the main pin. CALIPER DISASSEMBLY 1. REMOVE SLIDING BUSHING Pull out the sliding bushing. 2. REMOVE MAIN PIN BOOT Pull out the main pin boot. 3. REMOVE DUST BOOTS (a) Place the caliper in vise. (b) Using a screwdriver and hammer, tap out the 2 dust boots. BR–217 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 4. REMOVE CYLINDER BOOT SET RING AND CYLIN– DER BOOT Using a screwdriver, remove the cylinder boot set ring and cylinder boot from the cylinder. 5. REMOVE PISTON (a) Place a piece of cloth or similar article between the piston and the caliper. (b) Use compressed air to remove the piston from the cylinder. CAUTION: Do not place your fingers in front of the piston when using compressed air. 6. REMOVE PISTON SEAL Using a screwdriver, remove the piston seal from the cylinder. REAR DISC BRAKE COMPONENTS INSPECTION AND REPAIR 1. MEASURE PAD LINING THICKNESS Using a ruler, measure the pad lining thickness. Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 1.0 mm (0.039 in.) Replace the pad if the pad’s thickness is at the mini– mum thickness or less, or if the pad has excessively uneven wear. BR–218 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 2. MEASURE DISC THICKNESS Using a micrometer, measure the disc thickness. Standard thickness: 10.0 mm (0.394 in.) Minimum thickness: 9.0 mm (0.354 in.) Replace the disc if the disc’s thickness is at the mini– mum thickness or less. Replace the disc or grind it on a lathe if it is badly scored or worn unevenly. 3. MEASURE DISC RUNOUT Measure the disc runout 10 mm (0.39 in.) from the outer edge of the disc. Maximum disc runout: 0.15 mm (0.0059 in.) If the runout is greater than the maximum, replace the disc. HINT: Before measuring the runout, confirm that the hub bearing play is within specification. 4. IF NECESSARY, REPLACE DISC (a) Remove the torque plate. (b) Remove the hub nuts of the temporarily installed disc and pull off the disc. (c) Install a new disc and loosely install the hub nuts. (d) Install the torque plate and tighten the mounting bolts. Torque: 47 N–m (475 kgf–cm, 34 ft–lbf) CALIPER ASSEMBLY 1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO PARTS INDICATED WITH ARROWS 2. INSTALL PISTON SEAL AND PISTON IN CYLINDER BR–219 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 3. INSTALL CYLINDER BOOT AND SET RING IN CYL– INDER 4. INSTALL DUST BOOTS (a) Place the caliper in vise. (b) Using a 19 mm socket wrench and hammer, tap in 2 new dust boots into the torque plate. (c) Confirm that the metal plate portion of the dust boot fits snugly in the torque plate. 5. INSTALL MAIN PIN BOOT 6. INSTALL SLIDING BUSHING CALIPER INSTALLATION 1. INSTALL MAIN PIN Install the main pin and torque the main pin installa– tion bolt. Torque: 26 N–m (270 kgf–cm. 20 ft–lbf) BR–220 BRAKE SYSTEM – REAR BRAKE(Disc Brake) 2. INSTALL 2 PADS Install 2 pads with the pad wear indicator plate facing upward. NOTICE: There should be no oil or grease adhering to the friction surfaces of the pads or the disc. 3. INSTALL CALIPER Install the caliper and torque the installation bolt. Torque: 20 N–m (200 k9f¿cm, 14 ft–lbf) 4. CONNECT FLEXIBLE HOSE Install the flexible hose on the caliper with 2 new gaskets. Torque: 29 N–m (300 kgf–cm, 21 ft–Ibf) HINT: Insert the flexible hose lock securely in the lock hole in the caliper. 5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 6. CHECK FOR LEAKS BR–221 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) REAR BRAKE (Parking Brake for Rear Disc Brake) COMPONENTS PARKING BRAKE DISASSEMBLY 1. REMOVE REAR WHEEL 2. REMOVE REAR DISC BRAKE ASSEMBLY (a) Remove the 2 mounting bolts and remove the disc brake assembly. (b) Suspend the disc brake so the hose is not stretched. 3. REMOVE DISC HINT: If the disc cannot be removed easily, turn the shoe adjuster BR–222 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 4. REMOVE SHOE RETURN SPRINGS Using needle–nose pliers, remove the shoe return springs. 5. REMOVE FRONT SHOE, ADJUSTER AND TENSION SPRING (a) Slide out the front shoe and remove the shoe adjuster. (b) Remove the shoe strut with the spring. (c) Disconnect the tension spring and remove the front shoe. 6. REMOVE REAR SHOE (a) Slide out the rear shoe. (b) Remove the tension spring from the rear shoe. (c) Using needle–nose pliers, disconnect the parking brake cable from the parking brake shoe lever. (d) Remove the shoe hold–down spring cups, springs and pins. PARKING BRAKE COMPONENTS INSPECTION AND REPAIR 1. INSPECT DISASSEMBLED PARTS Inspect the disassembled parts for wear, rust or damage. BR–223 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 2. MEASURE BRAKE SHOE LINING THICKNESS Using a scale, measure the thickness of the shoe lining. Standard thickness: 2.0 mm (0.079 in.) Minimum thickness: 1.0 mm (0.039 in.) If the lining thickness is at the minimum thickness or less, or if there is excessively uneven wear, replace the brake shoe. 3. MEASURE DISC INSIDE DIAMETER Using a vernier caliper, measure the inside diameter of the disc. Standard inside diameter: 170 mm (6.69 in.) Maximum inside diameter: 171 mm (6.73 in.) Replace the disc if the inside diameter is at the maxi– mum value or more. Replace the disc or grind it with a lathe if the disc is badly scored or worn unevenly. 4. INSPECT PARKING BRAKE LINING AND DISC FOR PROPER CONTACT Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit. If the contact between the disc and the brake shoe lining is improp– er, repair it using a brake shoe grinder or replace the brake shoe assembly. 5. MEASURE CLEARANCE BETWEEN PARKING BRAKE SHOE AND LEVER Using a feeler gauge, measure the clearance. Standard clearance: Less than 0.35 mm (0.0138 in.) If the clearance is not within the specification, replace the shim with one of the correct size. Shim Thickness Shim Thickness 0.3 mm (0.012 in.) 0.9 mm (0.035 in.) 0.6 mm (0.024 in.) BR–224 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 6. IF NECESSARY, REPLACE SHIM (a) Remove the parking brake lever, and install the cor– rect size shim. (b) Install the parking brake lever with a new C–washer. (c) Remeasure the clearance. PARKING BRAKE ASSEMBLY HINT: Assemble the parts in the correct direction as shown. BR–225 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 1. APPLY HIGH TEMPERATURE GREASE ON BACK – ING PLATE 2. APPLY HIGH TEMPERATURE GREASE TO ADJUSTER 3. CONNECT PARKING BRAKE CABLE TO PARKING BRAKE LEVER (a) Install the shoe hold–down springs, cups and pins. (b) Using needle–nose pliers, connect the parking brake cable to the parking brake lever. 4. INSTALL REAR SHOE Slide in the rear shoe between the shoe hold–down spring cup and the backing plate. NOTICE: Do not allow oil or grease to get on the rubbing faces. 5. INSTALL TENSION SPRING, FRONT SHOE, AD– JUSTER AND STRUT (a) Install the tension spring to the rear shoe. (b) Install the front shoe to the tension spring. (c) Install the adjuster between the front and rear shoes. BR–226 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) (d) Install the shoe strut with the spring. (e) Slide in the front shoe between the shoe hold–down spring cup and the backing plate. 6. INSTALL SHOE RETURN SPRINGS Using needle–nose pliers, install the shoe return spr– ings. 7. INSTALL DISC (a) Before installing, polish the disc and shoe surfaces with sandpaper. (b) Align the hole on the rear axle hub flange and service hole on the disc. 8. ADJUST PARKING BRAKE SHOE CLEARANCE (a) Temporarily install the hub nuts. (b) Remove the hole plug. (c) Turn the adjuster and expand the shoes until the disc locks. (d) Return the adjuster 8 notches. (e) install the hole plug. BR–227 BRAKE SYSTEM – REAR BRAKE(Parking Brake for Rear Disc Brake) 9. INSTALL DISC BRAKE ASSEMBLY Install the disc brake assembly and torque the 2 mot nting bolts. Torque: 47 N–m (475 kgf–cm, 34 ft–lbf) 10. INSTALL REAR WHEEL 11. SETTLING PARKING BRAKE SHOES AND DISC (a) LEVER TYPE: With the parking brake release button pushed in, pull the lever with 98 N (10 kgf, 22 lbf) of force. (b) PEDAL TYPE: Depress the parking brake pedal with 147 N (15 kgf, 33 lbf). (c) Drive the vehicle at about 50 km/h (31 mph) on a safe, level and dry road. (d) Drive the vehicle for about 400 meters (0.25 mile) in this condition. (e) Repeat this procedure 2 or 3 times. 12. RECHECK AND ADJUST PARKING BRAKE LEVER/ PEDAL TRAVEL BR–228 BRAKE SYSTEM – PARKING BRAKE PARKING BRAKE PARKING BRAKE PEDAL DISASSEMBLY AND ASSEMBLY Remove and install the parts as shown. MAIN POINT OF PEDAL INSTALLATION INSTALL SHOCK ABSORBER (a) Loosen the union lock nut. (b) Install the shock absorber to the pin on the pedal bracket side, then extend the piston rod fully. (c) Return the pedal until it hits the cushion. (d) Make adjustments so that the shock absorber’s union and the pin on the pedal side are aligned, then turn the union 1 turn counterclockwise. (e) Install the shock absorber to the pedal and tighten the lock nut. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) BR–229 BRAKE SYSTEM – PARKING BRAKE PARKING BRAKE INTERMEDIATE LEVER DISASSEMBLY AND ASSEMBLY Remove and install the parts as shown. MAIN POINT OF INTERMEDIATE LEVER INSTALLATION MEASURE CLEARANCE BETWEEN INTERMEDIATE LEVER SHAFT AND LEVER Using a feeler gauge, measure the clearance. Standard clearance: 0.09–0.5 mm (0.004–0.02 in.) If the clearance is not within the specification, replace the shim with one of the correct size. Shim Thickness Shim Thickness 0.3 mm (0.012 in.) 1.2 mm (0.047 in.) 0.6 mm (0.024 in.) 1.5 mm (0.059 in.) 0.9 mm (0.035 in.) 1.8 mm (0.071 in.) BR–230 BRAKE SYSTEM – PROPORTIONING VALVE (P VALVE) PROPORTIONING VALVE (P VALVE) P VALVE INSPECTION 1. CONNECT FLUID PRESSURE GAUGE TO P VALVE 2. BLEED AIR FROM FLUID ’PRESSURE GAUGE 3. RAISE MASTER CYLINDER PRESSURE AND CHECK REAR WHEEL CYLINDER PRESSURE Master cylinder fluid pressure Rear brake cylinder fluid pressure 5S–FE w/o ABS: 2,452 kPa (25 kgf/cm2 , 356 psi) 7,845 kPa (80 kgf/cm2 , 1,138 psi) 2,452 kPa (25 kgf/cm2 , 356 psi) 4,452 kPa (45.4 kgf/cm2 , 648 psi) 1 MZ–FE w/o A6S: 2,942 kPa–(30 kgf/cm2 , 427 psi) 2,942 kPa (30 kgf/cm2 , 427 psi) 7,845 kPa (80 kgf/cm2 , 1,138 psi) 4,756 kPa (48.5 kgf/cm2 , 690 psi) 5S–FE w/ABS, 1 MZ–FE w/ABS: 3,432 kPa (35 kgf/cm2 , 498 psi) 7,845 kPa (80 kgf/cm2 , 1,138 psi) 3,432 kPa (35 kgf/cm2 , 498 psi) 5,070 kPa (51.7 kgf/crn2 , 735 psi) If the rear brake cylinder pressure is incorrect, replace the P valve assembly. 4. BLEED BRAKE SYSTEM 5. CHECK FOR LEAKS BR–231 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) LOAD SENSING PROPORTIONING VALVE (LSPV) COMPONENTS FLUID PRESSURE INSPECTION 1. SET REAR AXLE LOAD (a) Set the vehicle to its curb weight. (b) Measure the rear axle load and note the value. (c) Set the rear axle load. Rear axle load: Rear axle curb weight + 31 kg (68 Ib) 2. INSTALL LSPV GAUGE (SST) AND BLEED BRAKE SYSTEM SST 09709–.29017 BR–232 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) 3. RAISE FRONT BRAKE FLUID PRESSURE TO FOL– LOWING SPECIFICATION AND CHECK REAR BRAKE FLUID PRESSURE Rear brake fluid pressure: 5S–FE All, 1 MZ–FE w/ABS Front brake fluid pressure kPa (kgf/cm2 , psi) 9,807 (100, 1,422) Rear brake fluid pressure kPa (kgf/cm2 , psi) 6,139–7,120 (62.6–72.6, 890–1,033) 1 MZ–FE w/o A6S Front brake fluid pressure kPa (kgf/cm2 , psi) 12,747 (130 , 1,849) Rear brake fluid pressure kPa (kgf/cm2 , psi) 8,865–9,846 (90.4–100.4,1,286–1,428) HINT: • Depress the brake pedal while the engine is run– ning. • The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear pressure 2 sec– onds after adjusting to the specified fluid pres– sure. 4. IF NECESSARY, ADJUST FLUID PRESSURE (a) Set the shaft length A to initial set length and tighten the adjusting bolt lock nut. Initial set length: 26.0 mm (1.02 in.) (b) Check the rear brake fluid pressure. (c) If not within the specification, adjust the fluid pres– sure by changing the shaft length. Low pressure–Lengthen A High pressure–Shorten A HINT:–For every full turn of the adjusting nut, the fluid pressure will change as follows: Fluid Pressure changed kPa (kgf/cm2, psi) 5S–FE All, 1 MZ–FE w/ABS 294 (3.0, 42.7) 1 MZ–FE w/o ABS 422 (4.3, 61.2) BR–233 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) (d) Torque the lock nut. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) If it cannot be adjusted, replace the valve body. LSPV REMOVAL 1. DISCONNECT BRAKE LINES Using SST, disconnect the brake lines from the valve body. SST 09751–36011 2. REMOVE LSPV ASSEMBLY (a) Remove the lock nut and disconnect the adjusting bolt from the rear suspension arm. (b) Remove the 2 mounting bolts and remove the LSPV assembly. LSPV INSTALLATION 1. INSTALL LSPV ASSEMBLY (a) Install the valve assembly with the 2 mounting bolts. Torque: 39 N–m (400 kgf–cm, 29 ft–lbf) (b) Install the adjusting nut to the adjusting bolt and then install the adjusting bolt to the rear suspension arm with the lock nut. BR–234 BRAKE SYSTEM – LOAD SENSING PROPORTIONING VALVE (LSPV) 2. CONNECT BRAKE LINES Using SST, connect the brake lines. SST 09751–36011 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 3. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–9) 4. CHECK FOR LEAKS 5. CHECK AND ADJUST FLUID PRESSURE (See page BR–63) 6. REMOVE LSPV GAUGE (SST) AND BLEED BRAKE SYSTEM 7. CHECK FOR LEAKS BR–235 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ANTI–LOCK BRAKE SYSTEM (ABS) DESCRIPTION • ABS controls the brake cylinder hydraulic pressure to all 4 wheels during sudden braking and braking on slippery road surfaces, preventing the wheels from locking. ABS provides the following benefits: (1) Steering round an obstacle with a greater degree of certainty even when panic braking. (2) Stopping during panic braking while keeping the effect up on stability and steerability to a minimum, even on curves. • In case a malfunction occurs, a diagnosis function and fail–safe system have been adopted for the ABS. • An ABS actuator manufactured by BOSCH is used on the Camry produced by TMM (Toyota Motor Manufacturing U.S.A., Inc.). BR–236 BRAKE SYSTEM SYSTEM PARTS LOCATION – ANTI–LOCK BRAKE SYSTEM (ABS) BR–237 BRAKE SYSTEM WIRING DIAGRAM TMC Made Vehicle/NIPPONDENSO ABS: – ANTI–LOCK BRAKE SYSTEM (ABS) BR–238 BRAKE SYSTEM WIRING DIAGRAM TMM Made Vehicle/BOSCH ABS: – ANTI–LOCK BRAKE SYSTEM (ABS) BR–239 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS TMC Made Vehicle/NIPPONDENSO ABS: Terminal No. Connection Symbol Right front solenoid Terminal No. Connection Symbol Left rear speed sensor Ground Right front speed sensor DLC2 DLC1, DLC2 ABS control (motor) relay monitor Stop light switch Sealed wiring harness Right rear speed sensor Left front speed sensor Left rear speed sensor Sealed wiring harness ABS control (solenoid) relay Ignition switch Left front solenoid Left rear solenoid Ground Right front speed sensor A8S control (solenoid) relay monitor Left front speed sensor ABS control (motor) relay Relay ground Battery Right rear solenoid ABS warning light Parking brake switch DLC1 Right rear speed sensor BR–240 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS TMM Made Vehicle/BOSCH ABS: Terminal No. Connection Symbol Terminal No. Symbol Connection A6S warning fight Battery Left rear speed sensor Ignition switch DLC1 Left rear speed sensor Right front speed sensor Right rear speed sensor Left front speed sensor Stop light switch Right front speed sensor DLC1, DLC2 Left front speed sensor Right rear speed sensor DLC1 Ground BR–241 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS STANDARD VALUE TMC Made Vehicle/NIPPONDENSO ABS: Symbols (Terminals No.) STD Voltage (V) Condition Always IG switch ON IG switch ON, ABS warning light OFF IG switch ON IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF IG switch ON, ABS warning light OFF IG switch ON, AIRS warning light ON IG switch ON, ABS warning light OFF IG switch ON, PKB switch ON, Fluid in M/C reservoir above MIN level IG switch ON, PKB switch OFF, Fluid in M/C reservoir above MIN level Stop light switch OFF Stop light switch ON IG switch ON, ABS warning light OFF !G switch ON lG switch ON AC generation IG switch ON Slowly turn right front wheel AC generation IG switch ON Slowly turn left front wheel AC generation IG switch ON Slowly turn right rear wheel AC generation IG switch ON Slowly turn left rear wheel BR–242 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ECU TERMINALS STANDARD VALUE TMM Made Vehicle/BOSCH ABS: Symbols (Terminals No.) STD Voltage (V) Condition Always IG switch ON IG switch ON, A6S warning light ON IG switch ON, ABS warning light OFF IG switch ON, ABS warning light ON IG switch ON, ABS warning light OFF Stop light switch OFF Stop light switch ON lG switch ON I G switch 0 N AC generation IG switch ON, slowly turn right front wheel AC generation IG switch ON, slowly turn left front wheel AC generation IG switch ON, slowly turn right rear wheel AC generation IG switch ON, slowly turn left rear wheel BR–243 BRAKE SYSTEM – ANT!–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR (TMC Made Vehicle NIPPONDENSO ABS) ABS ACTUATOR REMOVAL AND INSTALLATION Remove and install the parts as shown. BR–244 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) MAIN POINTS OF REMOVAL AND INSTALLATION 1. DISCONNECT AND CONNECT BRAKE LINE Using SST, disconnect and connect the brake lines from/to the ABS actuator. SST 09023–00100 Torque: 15 N–m (155 kgf–cm. 11 ft–lbf) 2. BLEED BRAKE SYSTEM (See page BR–9) BR–245 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR INSPECTION 1. INSPECT BATTERY POSITIVE VOLTAGE Battery positive voltage: 10–14.5 V 2. DISCONNECT CONNECTORS (a) Disconnect the connector from the actuator. (b) Disconnect the 2 connectors from the control relay. 3. CONNECT ACTUATOR CHECKER (SST) TO ACTUA – TOR (a) Connect the actuator checker (SST) to the actuator, control relay and body side wire harness through the sub–wire harness C and E (SST) as shown. SST 09990–00150, 09990–00200, 09990–00210 (b) Connect the red cable of the checker to the battery positive (+) terminal and black cable to the negative (–) terminal. Connect the black cable of the sub–wire harness to the battery negative (–) terminal or body ground. BR–246 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) (c) Place the ”SHEET A” (SST) on the actuator checker. SST 09990–00163 4. INSPECT BRAKE ACTUATOR OPERATION (a) Start the engine, and run it at idle. (b) Turn the selector switch of the actuator checker to ”FRONT RH” position. (c) Push and hold in the MOTOR switch for a few sec– onds. (d) Depress the brake pedal and hold it until step (g) is com pleted. (e) Push the POWER SWITCH, and check that the brake pedal does not go down. NOTICE: Do not keep the POWER SWITCH pushed down for more than 10 seconds. (f) Release the switch, and check that the pedal goes down. – (g) Push and hold in the MOTOR switch for a few sec onds, and check that the pedal returns. (h) Release the brake pedal. (i) Push and hold in the MOTOR switch for a few sec– onds. (j) Depress the brake pedal and hold it for about 15 seconds. As you hold the pedal down, push the MOTOR switch for a few seconds. Check that the brake pedal does not pulsate. (k) Release the brake pedal. BR–247 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) (l) Turn the selector switch to ”FRONT LH” position. (m) Repeat (c) to 6), checking the actuator operation sim– ilarly. (n) Similarly, inspect ”REAR RH” and ”REAR LH” position. HINT: When inspecting ”REAR LH” position, push the REAR LH switch instead of the POWER SWITCH, and you can inspect in any selector switch position. (o) Push and hold in the MOTOR switch for a few sec– onds. (p) Stop the engine. 5. DISCONNECT ACTUATOR CHECKER (SST) FROM ACTUATOR Remove the ”SHEET A” (SST) and disconnect the actuator checker (SST) and sub–wire harness (SST) from the actuator, control relay and body side wire harness. SST 09990–00150, 09990–00200, 09990–00210 , 09990–00163 6. CONNECT CONNECTORS (a) Connect the 2 connectors to the control relay. (b) Connect the connector to the actuator. 7. CLEAR DIAGNOSTIC TROUBLE CODES (See page BR–94) BR–248 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR (TMM Made Vehicle BOSCH ABS) ABS ACTUATOR REMOVAL AND INSTALLATION Remove and install the parts as shown. BR–249 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) MAIN POINTS OF REMOVAL AND INSTALLATION 1. DISCONNECT AND CONNECT BRAKE LINE Using SST, disconnect and connect the brake lines from/to the ABS actuator. SST 09751–36011 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 2. INSTALL ABS ACTUATOR NOTICE: Use the bolts which have a notch to securely ground the actuator ground wire. 3. BLEED BRAKE SYSTEM (See page BR–9) BR–250 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS ACTUATOR DISASSEMBLY AND ASSEMBLY Remove and install the parts as shown. BR–251 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) MAIN POINTS OF DISASSEMBLY AND ASSEMBLY 1. REMOVE AND INSTALL COVER Using a T15 torx wrench, loosen and tighten the screw. Torque: 1.4 N–m(14 kgf–cm, 12 in.lbf) 2. DISCONNECT AND CONNECT 4–PIN AND 6–PIN CONNECTORS NOTICE: When installing, place the 4–pin connector’s cables into the cable guide. 3. REMOVE AND INSTALL ECU Using T15 and T20 torx wrenches, loosen and tighten the 5 screws. Torque: 1.7 N–m(17 kgf–cm, 15 in.–Ibf) NOTICE: There are 2 kinds of screw, so install a correct screw into each hole. 4. PERFORM TEST DRIVE (a) Drive for at least 20 seconds at 30 Km/h (119 mph). (b) The ABS warning light may not light. If the ABS warning light lights, read the diagnostic trouble code. BR–252 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) FRONT SPEED SENSOR COMPONENTS FRONT SPEED SENSOR AND SENSOR ROTOR SERRATIONS INSPECTION (REFERENCE) INSPECT FRONT SPEED SENSOR AND SENSOR ROTOR SERRATIONS BY USING AN OSCILLO– SCOPE (a) Connect an oscilloscope to the speed sensor connec– tor. (b) Run the vehicle at 20 km/h (112.4 mph), and inspect speed sensor output wave. (c) Check that C is 0.5 V or more. If not as specified, replace the speed sensor. (d) Check that B is 30% or more of A. If not as specified, replace the drive shaft. FRONT SPEED SENSOR REMOVAL 1. DISCONNECT SPEED SENSOR CONNECTOR (a) Remove the fender shield. (b) Disconnect the speed sensor connector. BR–253 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) 2. REMOVE SPEED SENSOR (a) Remove the 3 clamp bolts holding the sensor harness to the body and shock absorber_ (b) Remove the speed sensor from the steering knuckle. FRONT SPEED SENSOR INSTALLATION 1. INSTALL SPEED SENSOR Install the speed sensor to the steering knuckle. Torque: 7.8 N–m (80 kgf–cm, 69 MAW) 2. CONNECT SPEED SENSOR CONNECTOR (a) Install the sensor harness. Torque: 5.4 N–m (55 kgf–cm. 48 in.–lbf) (b) Connect the speed sensor connector. ¿¿”–07 BR–254 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) REAR SPEED SENSOR COMPONENTS REAR SPEED SENSOR AND SENSOR ROTOR SERRATIONS INSPECTION (REFERENCE) INSPECT REAR SPEED SENSOR AND SENSOR ROTOR SERRATIONS BY USING AN OSCILLO– SCOPE (a) Connect an oscilloscope to the speed sensor connec– tor. (b) Run the vehicle at 20 km/h (12.4 mph), and inspect speed sensor output wave. (c) Check that C is 0.5 V or more. If not as specified, replace the speed sensor. (d) Check that B is 40 96 or more of A. If not as specified, replace the rear axle hub. BR–255 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) REAR SPEED SENSOR REMOVAL 1. DISCONNECT SPEED SENSOR CONNECTOR (a) Remove the seat cushion and side seatback. (b) Disconnect the speed sensor connector, and pull out the sensor wire harness with the grommet. (c) Remove the 2 clamp bolts holding the sensor wire harness to the body and shock absorber. 2. REMOVE SPEED SENSOR Remove the speed sensor from the axle carrier. REAR SPEED SENSOR INSTALLATION 1. INSTALL SPEED SENSOR Install the speed sensor to the axle carrier. Torque: 7.8 N–m (80 kgf–cm, 69 in.lbf) 2. CONNECT SPEED SENSOR CONNECTOR (a) Pass the sensor harness through the body panel hole, and connect the connector. BR–256 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) (b) install the grommet securely. (c) Install the sensor harness. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) BR–257 BRAKE SYSTEM –MEMO– – ANTI–LOCK BRAKE SYSTEM (ABS) BR–258 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING (TMC Made Vehicle NIPPONDENSO ABS) HOW TO PROCEED WITH TROUBLESHOOTING Perform troubleshooting in accordance with the procedure on the following pages. (1) CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in as much detail as possible about the problem. (2) CHECK AND CLEAR THE DIAGNOSTIC TROUBLE CODES (PRECHECK) If the ABS warning light lights up, and the ABS does not operate, the ECU stores diagnostic trouble codes corresponding to the problem in memory. Before confirming the trouble, first check the diagnostic trouble codes to see if there are any malfunction codes stored in memory. When there are malfunction codes, make a note of them, then clear them and proceed to ”3” Problem Symptom Confirmation”. (3) PROBLEM SYMPTOM CONFIRMATION, (4) SYMPTOM SIMULATION Confirm the problem symptoms. If the problem does not recur, simulate the problem by initially checking the circuits indicated by the diagnostic trouble code in step “2” , using ”Problem simulation method”. (5) DIAGNOSTIC TROUBLE CODE CHECK Check the diagnostic trouble codes. If a malfunction code is output, proceed to ” 6” Diagnostic Trouble Code Chart”. If the normal code is output, proceed to ” 7” Problem Symptoms Chart”. Be sure to proceed to ” 6” Diagnostic Trouble Code Chart” after steps “2” and “3” are completed. If troubleshooting is attempted only by following the malfunction code stored in the memory, errors could be made in the diagnosis. (6) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is confirmed in the diagnostic trouble code check, proceed to the inspection procedure indicated by the matrix chart for each diagnostic trouble code. (7) PROBLEM SYMPTOMS CHART If the normal code is confirmed in the diagnostic trouble code check, perform inspection in accordance with the inspection order in the problem symptoms chart. (8) CIRCUIT INSPECTION Proceed with diagnosis of each circuit in accordance with the inspection order confirmed in 6 and 7 . Determine whether the cause of the problem is in the sensor, actuators, wire harness and connectors, or the ECU. (9) SENSOR CHECK Use the ABS warning light to check if each of the signals from the speed sensors are being input correctly to the ECU. Instructions for this check are given in the circuit inspection. (10) REPAIRS After the cause of the problem is located, perform repairs by following the inspection and replacement procedures in this manual. (11) CONFIRMATION TEST After completing repairs, confirm not only that the malfunction is eliminated, but also conduct a test drive to make sure the entire ABS system is operating correctly. BR–259 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Items inside are titles of pages in this manu– al, with the page number in the bottom portion. See the pages for detailed explanations. Vehicle brought to workshop Customer Problem Analysis P. BR–92 2 Check and Clear Diagnostic Trouble Code Precheck) P. BR–93BR–94 Symptom does not occur 3 Problem Symptom Confirmation Symptom Simulation P.!N–21 Symptom occurs 5 Normal code Diagnostic Trouble Code Check P. BR–93 6 Diagnostic Trouble Code Chart Problem Symptoms Chart P. BR–95 Circuit Inspection P. BR–98 Sensor Check Check for Fluid Leakage P. BR–108BR–138 P. BR–139 Identification of Problem 10 Repair Confirmation Test End Step 5 8 Diagnostic steps permitting the use of the TOYOTA hand–held tester or TOYOTA break–out–box. BR–260 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) CUSTOMER PROBLEM ANALYSIS CHECK SHEET BR–261 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSIS SYSTEM INDICATOR CHECK When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. HINT: If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit (See page BR– 130). DIAGNOSTIC TROUBLE CODE CHECK 1. Disconnect the Short Pin from DLC1. 2. Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 09843–18020 3. Turn the ignition switch to ON. 4. Read the diagnostic trouble code from the ABS warning light on the combination meter. HINT: If no code appears, inspect the diagnostic circuit or ABS warning light circuit (See page BR–134 or BR–130). As an example, the blinking patterns for normal code and codes 11 and 21 are shown on the left. 5. Codes are explained in the code table on page BR–95. 6. After completing the check, disconnect terminals Tc and E1, and turn off the display. If 2 or more malfunctions are indicated at the same time, the–lowest numbered diagnostic trouble code will be displayed first. . BR–262 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Hook up the Toyota hand–held tester to the DLC2. 2. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the Toyota hand–held tester operator’s manual for further details. DIAGNOSTIC TROUBLE CODE CLEARANCE 1. Using SST, connect terminals Tc and E1 of DLC2 or DLC1 and remove the short pin from DLC1. SST 09843–18020 2. IG switch ON. 3. Clear the diagnostic trouble codes stored in ECU by de– pressing the brake pedal 8 or more times within 3 seconds. 4. Check that the warning light shows the normal code. 5. Remove the SST from the terminals of DLC2 or DLC1. 6. Connect the Short Pin to DLC1 HINT: Cancellation can also be done by removing the ECU–13 fuse, but in this case, other memory systems will also be cancelled out. ECU TERMINAL VALUES MEASUREMENT USING TOYOTA BREAK–OUT–BOX AND TOYOTA HAND–HELD TESTER 1. Hook up the Toyota break–out–box and Toyota hand–held tester to the vehicle. 2. Read the ECU input/output values by following the prompts on the tester screen. HINT: Toyota hand–held tester has a ”Snapshot” function. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the Toyota hand–held tester/Toyota break– out–box operator’s manual for further details. BR–263 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check, check the circuit listed for that code. HINT: Using SST 09843–18020, connect the terminals Tc and E1, and remove the short pin. Code ABS Warning Light Blinking Pattern Diagnosis Open circuit in ABS control (solenoid) relay circuit Short circuit in ABS control (solenoid) relay circuit Open circuit in ABS control (motor) relay circuit Short circuit in ABS control (motor) relay circuit Open or short circuit in 3–position solenoid circuit for right front wheel Open or short circuit in 3–position solenoid circuit for left front wheel Open or short circuit in 3–position solenoid circuit for right rear wheel Open or short circuit in 3–position solenoid circuit for left rear wheel Right front wheel speed sensor signal malfunction Left front wheel speed sensor signal malfunction Right rear wheel speed sensor signal malfunction Left rear wheel speed sensor signal malfunction Open circuit in left front or right rear speed sensor circuit Open circuit in right front or left rear speed sensor circuit Faulty rear speed sensor rotor Low battery positive voltage or abnormally high battery positive voltage Pump motor is locked Open in pump motor ground Always ON Malfunction in ECU BR–264 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) SPEED SENSOR SIGNAL CHECK 1. Turn the ignition switch to OFF. 2. Using SST, connect terminals Ts and E1 of DLC1. SST 09843–18020 3. Start the engine. 4. Check that the ABS warning light blinks HINT: If the ABS. warning light does not blink, inspect the ABS warning light circuit (See page BR–130). 5. Drive vehicle straight forward. HINT: Drive vehicle faster than 45 km/h (28 mph) for several seconds. 6. Stop the vehicle. 7. Using SST, connect terminals Tc and E1 of DLC1. SST 09843–18020 8. Read the number of blinks of the ABS warning light. HINT: See the list of diagnostic trouble codes shown on the next page. If every sensor is normal, a normal code is output (A cycle of 0.25 sec. ON and 0.25 sec. OFF is repeated). If 2 or more malfunctions are indicated at the same time, the lowest numbered code will be displayed first. 9. After performing the check, disconnect terminals Ts and E1, Tc and E1 of DLC1, and ignition switch turned off. BR–265 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Perform steps 1.–6. on the previous page. 2. Hook up the Toyota hand–held tester to the DLC2. 3. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the Toyota hand–held tester operator’s manual for further details. Diagnostic Trouble Code of Speed Sensor Check Function Code No. Diagnosis Trouble Area Low output voltage of right front speed sensor • • Right front speed sensor Sensor installation Low output voltage of left front speed sensor • • Left front speed sensor Sensor installation Low output voltage of right rear speed sensor • • Right rear speed sensor Sensor installation Low output voltage of left rear speed sensor • • Left rear speed sensor Sensor installation Abnormal change in output voltage of right front speed sensor • Right front speed sensor rotor Abnormal change in output voltage of left front speed sensor • Left front speed sensor rotor Abnormal change in output voltage of right rear speed sensor • Right rear speed sensor rotor Abnormal change in output voltage of left rear speed sensor • Left rear speed sensor rotor BR–266 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) PROBLEM SYMPTOMS CHART If a normal code is displayed during the diagnostic trouble code check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. Inspection Circuit Symptoms A6S does not operate. A6S does not operate efficiently. ABS warning light abnormal. Diagnostic trouble code check cannot be performed. Speed sensor signal check cannot be performed. Only when 1.–4. are all normal and the problem is still occurring, replace the ABS ECU. 1. Check the diagnostic trouble code, reconfirming that the normal code is output. 2. IG power source circuit. 3. Speed sensor circuit. 4. Check the ABS actuator with a checker. If abnormal, check the hydraulic circuit for leakage (see page BR–139). Only when 1.–4. are all normal and the problem is still occurring, replace the ABS ECU. 1. Check the diagnostic trouble code, reconfirming that the normal code is output. 2. Speed sensor circuit. 3. Stop light switch circuit. 4. Check the ABS actuator with a checker. If abnormal, check the hydraulic circuit for leakage (see page BR–139). 1. ABS warning light circuit. 2. ABS ECU. Only when 1. and 2. are all normal and the problem is still occurring, replace the ABS ECU. 1. ABS warning light circuit. 2. Tc terminal circuit. 1. Ts terminal circuit. 2. ABS ECU. See page BR–93 BR–123 BR–119 BR–77 BR–93 BR–119 BR–128 BR–77 BR–130 BR–130 BR–134 BR–137 BR–267 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) LOCATION OF CONNECTORS Location of Connectors in Engine Compartment 1MZ–FE Engine: BR–268 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–269 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in Engine Compartment 5S–FE Engine: BR–270 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–271 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in Instrument Panel BR–272 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–273 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–274 BRAKE SYSTEM – J/B No. 1 J/B No. 3 ANTI–LOCK BRAKE SYSTEM (ABS) BR–275 BRAKE SYSTEM Location of Connectors in Body – ANTI–LOCK BRAKE SYSTEM (ABS) BR–276 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) CIRCUIT INSPECTION DTC 11,12 ABS Control (Solenoid) Relay Circuit CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. DTC No. Diagnostic Trouble Code Detecting Condition Conditions (1) and (2) continue for 0.2 sec. or more: (1) ABS control (solenoid) relay terminal (SR) voltage: Battery positive voltage (2) ABS control (solenoid) relay monitor termi– nal (AST) voltage: 0 V Conditions (1) and (2) continue for 0.2 sec. or more: (1) ABS control (solenoid) relay terminal (SR) voltage: 0 V (2) ABS control (solenoid) relay monitor termi– nal (AST) voltage: Battery positive voltage Trouble area • • • ABS control (solenoid) relay. Open or short in ABS control (solenoid) relay circuit. ECU. • • • ABS control (solenoid) relay. B+ short in ABS control (solenoid) relay circuit. ECU. Fail safe function: If trouble occurs in the control (solenoid) relay circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. DIAGNOSTIC CHART Check voltage of ABS control relay connector. Check and repair harness or connector. Check continuity between relay and actuator and ECU. Repair or replace harness or ABS ac– tuator. Check ABS control relay. Replace ABS control relay. Check for open and short in harness and con– nector between relay and ECU. Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–277 BRAKE SYSTEM WIRING DIAGRAM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–278 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE 2 and Check voltage between terminals connector. 6 of ABS control relay Disconnect the ABS control relay connector. Measure voltage between terminals A72 and A76 of ABS control relay harness side connec– tor. Voltage: 10–14 V Check and repair harness or connector. Check continuity between terminals A4 2, A4 2 and A13 18. 5 and 4 and Disconnect the 2 connectors from ABS actuator. Check continuity between terminals A7 5 and A5 4, A5 4 and A4 2, A4 2 and A13 18. Continuity HINT: There is a resistance of 4–6 between terminals A5 4 and A4 2. Repair or replace harness or ABS actuator. BR–279 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check ABS control relay. Check continuity between each terminal of ABS control relay. Continuity (Reference value 80) Terminals 1 and Terminals 5 and Continuity Terminals 2 and Open 1. Apply battery positive voltage between termi– nals A7 1 and A6 3. 2. Check continuity between each terminal of ABS control relay. Terminals Terminals 5 a rid Open 2 and Continuity Replace ABS control relay. Check for open and short in harness and connector between ABS control relay a ABS ECU (See page IN–28). Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–280 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 13,14 ABS Control (Motor) Relay Circuit CIRCUIT DESCRIPTION The ABS control (motor) relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches the control (motor) relay ON and operates the ABS pump motor. DTC No. Diagnostic Trouble Code Detecting Condition Conditions (1) and (2) continued for 0.2 sec. or more: (1) ABS control (motor) relay terminal (MR) voltage: Battery positive voltage (2) ABS control (motor) relay monitor terminal (MT) voltage: 0 V Conditions (1) and (2) continued for 4 sec. or more: (1) ABS control (motor) relay terminal (MR) voltage: 0 V (2) ABS control (motor) relay monitor terminal (MT) voltage: Battery positive voltage Fail safe function: Trouble area • • • ABS control (motor) relay. Open or short in ABS control (motor) relay circuit. ECU. • • • ABS control (motor) relay. B+ short in ABS control (motor) relay circuit. ECU. If trouble occurs in the control (motor) relay circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. DIAGNOSTIC CHART Check voltage of ABS control relay connector. Check and repair harness or connector. Check continuity between relay and pump motor and ECU. Repair or replace harness or ABS ac– tuator. Check ABS control relay. Replace ABS control relay. Check for open and short in harness and con– nector between relay and ECU. Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–281 BRAKE SYSTEM WIRING DIAGRAM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–282 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals ground. 1 of ABS control relay and body Disconnect the ABS control relay connector. Measure voltage between terminals A6 1 of ABS control relay harness side connector and body ground. Voltage: 10–14 V Check and repair harness or connector. Check continuity between terminals A4 5, A4 5 and A13 6. 2 and 3 and Disconnect the 2 connectors from ABS actuator. Check continuity between terminals A6 2 and A5 3, A5 3 and A4 5, A4 5 and A13 6. Continuity HINT: There is a resistance of 4–6 between terminals A5 3 and A4 5. Repair or replace harness or ABS actuator. BR–283 BRAKE SYSTEM – LOCK BRAKE SYSTEM (ABS) Check ABS control relay. Check continuity between each terminal of ABS control relay. Terminals 3 and Continuity (Reference value 62
Terminals 1 and Open 1. Apply battery positive voltage between termi– nals A6 3 and A6 4. 2. Check continuity between each terminal of ABS control relay. Terminals 1 and Continuity Replace ABS control relay. Check for open and short in harness and connector between ABS control relay and ABS ECU (See page IN–28). Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–284 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 21 22 23 24 ABS Actuator Solenoid Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders, thus controlling the braking force. DTC No. Diagnostic Trouble Code Detecting Condition Conditions (1) through (3) continue for 0.05 sec. or more: (1) ABS control (solenoid) relay terminal (SR) • voltage: Battery positive voltage • (2) Voltage of ABS ECU terminal • AST: Battery positive voltage (3) When power transistor of ECU is ON, voltage of terminal SFR is 0 V or battery positive voltage. Conditions (1) through (3) continue for 0.05 sec. or more: (1) ABS control (solenoid) relay terminal (SR) • voltage: Battery positive voltage • (2) Voltage of ABS ECU terminal • AST: Battery positive voltage (3) When power transistor of ECU is ON, voltage of terminal SFL is 0 V or battery positive voltage. Trouble area ABS actuator. Open or short in SFR circuit. ECU. ABS actuator. Open or short in SFL circuit. ECU. Conditions (1) through (3) continue for 0.05 sec. or more: (1) ABS control (solenoid) relay terminal (SR) • voltage: Battery positive voltage • (2) Voltage of ABS ECU terminal • AST: Battery positive voltage (3) When power transistor of ECU is ON, voltage of terminal SRR is 0 V or battery positive voltage. ABS actuator. Open or short in SRR circuit. ECU. Conditions (1) through (3) continue for 0.05 sec. or more: (1) ABS control (solenoid) relay terminal (SR) • voltage: Battery positive voltage • (2) Voltage of ABS ECU terminal • AST: Battery positive voltage (3) When power transistor of ECU is ON, voltage of terminal SRL is 0 V or battery positive voltage. ABS actuator. Open or short in SRL circuit. ECU. Fail safe function: If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the control (solenoid) relay and prohibits ABS control. DIAGNOSTIC CHART Check ABS actuator solenoid. Replace ABS actuator. Check for open and short in harness and con– nector between ECU and actuator. Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–285 BRAKE SYSTEM WIRING DIAGRAM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–286 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check ABS actuator solenoid. Disconnect the 2 connectors from ABS actuator. Check continuity between terminals A5 4and A4 1, 3, 4, 6 of ABS actuator connector. Continuity HINT: Resistance of each solenoid coil is 1.2. Replace ABS actuator. Check for open and short in harness and connector between ABS ECU and actuator (See page IN–28). Repair or replace harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–287 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 31, 32, 33, 34, 35, 36 Speed Sensor Circuit CIRCUIT DESCRIPTION The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system. The front and rear rotors each have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. DTC No. 31,32, 33,34 Trouble area Diagnostic Trouble Code Detecting Condition Detection of any of conditions (1) through (3): (1) At vehicle speed of 10 km/h (6 mph) or more, pulses are not input for 5 sec. (2) Momentary interruption of the speed sensor signal occurs at least 7 times in the time be– tween switching the ignition switch ON and switching it OFF. (3) Abnormal fluctuation of speed sensor signals with the vehicle speed 20 km/h (12 mph) or more. Speed sensor signal is not input for about 1 sec. while the left front and right rear speed sensor signals are being checked with the IG switch ON. Speed sensor signal is not input for about 1 sec. while the right front and left rear speed sensor signals are being checked with the IG switch ON. • Right front, left front, right rear and left rear speed sensor. Open or short in each speed sensor circuit. ECU. • • • • • Open in left front or right rear speed sensor circuit. ECU. Open in right front or left rear speed sensor circuit. • ECU. HINT: DTC No. 31 is for the right front speed sensor. DTC No. 32 is for the left front speed sensor. DTC No. 33 is for the right rear speed sensor DTC No. 34 is for the left rear speed sensor. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and prohibits ABS control. BR–288 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC CHART Check speed sensor. Replace speed sensor. Check for open and short in harness and con– hector between each speed sensor and ECU. Repair or replace harness or connector. Check sensor rotor and sensor installation. Replace speed sensor or rotor. Check and replace ABS ECU. WIRING DIAGRAM BR–289 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check speed sensor. Front 1. Remove front fender liner. 2. Disconnect speed sensor connector. Measure resistance between terminals 1 and 2 of speed sensor connector. Resistance: 0.6–1.8 k
Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. Resistance: 1 M
or higher Rear 1. Remove the seat cushion and side seat back. 2. Disconnect speed sensor connector. Measure resistance between terminals 1 and 2 of speed sensor connector. Resistance: 0.9–1.3 k
Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. Resistance: 1 M
or higher Replace speed sensor. Check for open and short in harness and connector between each speed sensor and ECU (See page IN–28). Repair or replace harness or connector. BR–290 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check sensor rotor and sensor installation. Front Remove front drive shaft (See SA section). Check sensor–rotor serrations. No scratches or missing teeth. Check the front speed sensor installation The installation bolt is tightened properly. Rear Remove the axle hub (See SA section). Check the sensor rotor serrations. No scratches or missing teeth. Check the speed sensor installation The installation bolt is tightened properly and there is no clearance between the sensor and rear axle carrier. Replace speed speed or rotor. Check and replace ABS ECU. BR–291 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 41 IG Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the CPU and the actuators. DTC No. Trouble area Diagnostic Trouble Code Detecting Condition Vehicle speed is 3 km/h (1.9 mph) or more and voltage of ECU terminal IG1 remains at more than 17 V or below 9.5 V for more than 10 sec. • • • • Battery. IC regulator. Open or short in power source circuit. ECU. Fail safe function: If trouble occurs in the power source circuit, the ECU cuts oft current to the ABS control (solenoid) relay and prohibits ABS control. DIAGNOSTIC CHART Check battery positive voltage. Check and repair the charging system. Check voltage between terminals IG1 and GND of ABS ECU connector. Check and replace ABS ECU. Check continuity between terminals GND of ABS ECU connector and body ground. Repair or replace harness or connector. Check ECU–IG fuse. Check for short in all the harness and components connected to ECU–IG fuse (See attached wiring diagram). Check for open in harness and connector between ABS ECU and battery. BR–292 BRAKE SYSTEM WIRING DIAGRAM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–293 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Remove ABS ECU with connectors still connected. 1. Turn ignition switch ON. 2. Measure voltage between terminals IG1 and G N D of ABS ECU connector. Voltage: 10–14 V Check continuity between terminals GND of ABS ECU connector and body ground. Measure resistance between terminals GND of ABS ECU connector and body ground. Resistance: 1
or less BR–294 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check ECU–IG fuse. Remove ECU–IG fuse from J/6 No. 1. Check continuity of ECU–IG fuse. Continuity Check for short in all the harness and components connected to ECU–IG fuse (See attached wiring diagram). Check for open in harness and connector between ABS ECU and battery (See page IN–28). BR–295 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION DTC No. Diagnostic Trouble Code Detecting Condition Pump motor is not operating normally during initial check. Trouble area • ABS pump motor. Fail safe function: If trouble occurs in the ABS pump motor, the ECU cuts off current to the control (solenoid) relay and prohibits ABS control. DIAGNOSTIC CHART See inspection of ABS actuator (See page BR–77). WIRING DIAGRAM (Reference) BR–296 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Stop Light Switch Circuit CIRCUIT DESCRIPTION This stop light switch senses whether the brake pedal is depressed or released, and sends the signal to the ECU. DIAGNOSTIC CHART Check operation of stop light. Repair stop light circuit (See page BE– 65). Check voltage of terminal STP. Proceed to next circuit inspection shown on problem symptoms chart (See page BR–98). Check for open in harness and connector be– tween ABS ECU and stop light switch (See page IN–27). Repair or replace harness or connector. Check and replace ABS ECU. WIRING DIAGRAM BR–297 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check operation of stop light. Check that stop light lights up when brake pedal is depressed and turns off when brake pedal is released. Repair stop light circuit (See page BE–65). Check voltage between terminal STP of ABS ECU and body ground. Remove ABS ECU with connectors still connected. Measure voltage between terminal STP of ABS ECU and body ground when brake pedal is de– pressed. Voltage: 8–14 V Proceed to next circuit inspection shown on problem symptoms chart (See page BR–98). Check for open in harness and connector between ABS ECU and stop light switch (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. BR–298 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a diagnostic trouble code in memory. After removing the short pin of the DLC1, connect terminals Tc and E1 of the DLC1 or DLC2 to make the ABS warning light to blink and output the diagnostic trouble code. DIAGNOSTIC CHART Perform troubleshooting in accordance with the chart below for each trouble symptom. ABS warning light does not light up G o to step 1 . . ... ABS warning light remains on WIRING DIAGRAM Go to step 3 BR–299 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS warning light does not light up. Check ABS warning light. Repair or replace ABS warning light bulb or circuit. Check ABS control relay. Replace ABS control relay. Check for open in harness and connector between GAUGE fuse and J/B No. 3. A6S warning light remains on. Is diagnostic trouble code output? Does ABS warning light go off if short pin is removed? YES Repair circuit indicated by the code output. Check for–short in harness and connec– tor between warning light and DLC1 and ECU. YES Check ABS control relay. Check for short in harness and connector between DLC1 and ABS control relay. Replace ABS control relay. BR–300 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check ABS warning light. See Combination Meter Troubleshooting on page BE–1 18. Replace bulb or combination meter assembly. Check ABS control relay. Disconnect the connectors from control relay. Check continuity between each terminal of ABS control relay. Terminals 1 and Continuity (Reference value 80) Terminals 5 and Continuity Terminals 2 and Open 1. Apply battery positive voltage between termi– nals A7 1 and A6 3. 2. Check continuity between each terminal of ABS control relay. Terminals Terminals 5 and 2 and Open Continuity Connect the  test lead to terminal 4 of A7 and the  lead to terminal 5 of A7 . Check continuity between the terminals. Continuity If there is no continuity, connect the  test lead to terminal 4 of A7 and the  lead to terminal 5 of A7 . Recheck continuity between terminals. Replace ABS control relay. Check for open in harness and connector between DLC1 and A6S control relay and body ground (See page IN–27). BR–301 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Is diagnostic trouble code output? Perform diagnostic trouble code check on page BR–93. YES Repair circuit indicated by the code output. Does ABS warning light go off if short pin is removed? YES Check for short in harness and connector between warning light and DLC1 and ECU (See page IN–28 ). Check ABS control relay (See step No. 2). Replace ABS control relay. Check for short in harness and connector between DLC1 and ABS control relay (See page IN–28). BR–302 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Tc Terminal Circuit CIRCUIT DESCRIPTION Connecting terminals Te and E1 of the DLC1 or the DLC2 causes the ECU to display the diagnostic trouble code by flasing the ABS warning light. DIAGNOSTIC CHART Check voltage between terminals Tc and E1 of DLC2 or DLC 1. Check for open and short in harness and connec– tor between ABS ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN–28). Check and replace ABS ECU. If ABS warning light does not blink even after Tc and E1 are connected, the ECU may be defective.* Repair or replace harness or connector. *: Provided that the harness between terminal Tc of DLC2 or DLC1 and terminal Te of ECU is not open. BR–303 BRAKE SYSTEM WIRING DIAGRAM 1 MZ–FE: 5S–FE: – ANTI–LOCK BRAKE SYSTEM (ABS) BR–304 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals Te and E1 of DLC2 or DLC1. 1. Turn ignition switch ON. 2. Measure voltage between terminals Tc and E1 of DLC2 or DLC1. Voltage: 10–14 V If ABS warning light does not blink even after Tc and E1 are connected, the ECU may be defective. Check for open and short in harness and connector between ABS ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. BR–305 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which cannot be detected with the diagnostic trouble code check. Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check. DIAGNOSTIC CHART Check voltage between terminals Ts and E1 of DLC 1. If ABS warning light does not blink even after Ts and E 1 are connected, the ECU may be defective. Check for open and short in harness and connec– tor between ABS ECU and DLC1, DLC1 and body ground (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. WIRING DIAGRAM BR–306 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals and E1 of DLC1. 1. Turn ignition switch ON. 2. Measure voltage between terminals Ts and E1 of DLC 1. Voltage: 10–14 V If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective. Check for open and short in harness and connector between ABS ECU and DLC1, DLC1 and body ground (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. BR–307 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines. BR–308 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) TROUBLESHOOTING (TMM Made Vehicle BOSCH ABS) HOW TO PROCEED WITH TROUBLESHOOTING Perform troubleshooting in accordance with the procedure on the following pages. (1) CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in as much detail as possible about the problem. (2) CHECK AND CLEAR THE DIAGNOSTIC TROUBLE CODES (PRECHECK) If the ABS warning light lights up, and the ABS does not operate, the ECU stores diagnostic trouble codes corresponding to the problem in memory. Before confirming the trouble, first check the diagnostic trouble codes to see if there are any malfunc– tion codes stored in memory. When there are malfunction codes, make a note of them, then clear them and proceed to ”3” Problem Symptom Confirmation”. (3) PROBLEM SYMPTOM CONFIRMATION, (4) SYMPTOM SIMULATION Confirm the problem symptoms. If the problem does not recur, simulate the problem by initially checking the circuits indicated by the diagnostic trouble code in step 2 , using ”Problem simulation method”. (5) DIAGNOSTIC TROUBLE CODE CHECK Check the diagnostic trouble codes. If a malfunction code is output, proceed to ”6” Diagnostic Trouble Code Chart”. If the normal code is output, proceed to ” 7” “Problem Symptoms Chart”. Be sure to proceed to ” 6 “Diagnostic Trouble Code Chart” after steps “2” and “3” are completed. If troubleshooting is attempted only by following the malfunction code stored in the memory, errors could be made in the diagnosis. (6) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is confirmed in the diagnostic trouble code check, proceed to the inspection procedure indicated by the matrix chart for each diagnostic trouble code. (7) PROBLEM SYMPTOMS CHART If the normal code is confirmed in the diagnostic trouble code check, perform inspection in accordance with the inspection order in the problem symptoms chart. (8) CIRCUIT INSPECTION Proceed with diagnosis of each circuit in accordance with the inspection order confirmed in 6 and 7 . Determine whether the cause of the problem is in the sensor, actuators, wire harness and con– nectars, or the ECU. (9) SENSOR CHECK Use the ABS warning light to check if each of the signals from the speed sensors are being input correctly to the ECU. Instructions for this check are given in the circuit inspection. (10) REPAIRS After the cause of the problem is located, perform repairs by following the inspection and replacement procedures in this manual. (11) CONFIRMATION TEST After completing repairs, confirm not only that the malfunction is eliminated, but also conduct a test drive to make sure the entire ABS system is operating correctly. BR–309 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Items inside E7 are titles of pages in this manu– al, with the page number in the bottom portion. See the pages for detailed explanations. Vehicle brought to workshop Customer Problem Analysis P. BR–142 Check and Clear Diagnostic Trouble Code (Precheck) P. BR–143–BR–144 . Symptom does not occur . Symptom Simulation P. IN–21 Problem Symptom Confirmation .Symptom.. occurs Normal code Diagnostic Trouble Code Check Problem Symptoms Chart P. BR–143 P. BR–14$ Diagnostic Trouble Code Chart P. BR–160BR–184 Sensor Circuit Check Inspection P. BR–160–BR–184 Check for Fluid Leakage P. BR–185 Identification of Problem Repair Confirmation Test End Step 5. 9. : Diagnostic steps permitting the use of the TOYOTA hand–held. BR–310 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) CUSTOMER PROBLEM ANALYSIS CHECK SHEET BR–311 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSIS SYSTEM INDICATOR CHECK When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. HINT: If the indicator check result is not normal, proceed to troubleshooting for the ABS warning light circuit (See page BR– 177). DIAGNOSTIC TROUBLE CODE CHECK 1. Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 09843–18020 2. Turn the ignition switch to ON. 3. Read the diagnostic trouble code from the ABS warning light on the combination meter. HINT: If no code appears, inspect the diagnostic circuit or ABS warning light circuit (See page BR–180 or BR–177y. As an example, the blinking patterns for normal code and codes 11 and 21 are shown on the left. 4. Codes are explained in the code table on page BR–145. 5. After completing the check, disconnect terminals Tc and E1, and turn off the display. If 2 or more malfunctions are indicated at the same time, the lowest numbered diagnostic trouble code will be displayed first. BR–312 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Hook up the Toyota hand–held tester to the DLC2. 2. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the Toyota hand–held tester operator’s manual for further details. DIAGNOSTIC TROUBLE CODE CLEARANCE 1. Using SST, connect terminals Tc and E1 of DLC2 or DLC1. SST 09843–18020 2. IG switch ON. 3. Clear the diagnostic trouble codes stored in ECU by de– pressing the brake pedal 8 or more times within 3 seconds. 4. Check that the warning light shows the normal code. 5. Remove the SST from the terminals of DLC2 or DLC1. HINT: Cancellation cannot be done by removing the battery cable or ECU–13 fuse. BR–313 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check, check the circuit listed for that code. Code ABS Warning Light Blinking Pattern Diagnosis Open or short circuit in ABS solenoid relay circuit Open or short circuit in ABS motor relay circuit Open or short circuit in 3–position solenoid circuit for right front wheel Open or short circuit in 3–position solenoid circuit for left front wheel Open or short circuit in 3–position solenoid circuit for rear wheels Right front wheel speed sensor signal malfunction Left front wheel speed sensor signal malfunction Right rear wheel speed sensor signal malfunction Left rear wheel speed sensor signal malfunction Open circuit in right front speed sensor circuit Open circuit in left front speed sensor circuit Faulty rear speed sensor rotor Open circuit in right rear speed sensor circuit Open circuit in left rear speed sensor circuit Low battery positive voltage Pump motor is locked Open in pump motor circuit in actuator Malfunction in ECU BR–314 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) SPEED SENSOR SIGNAL CHECK 1. When the ignition switch is turned ON, check that the ABS warning light goes on for 3 seconds. 2. Turn the ignition switch to OFF. 3. Using SST, connect terminals Ts and El of DLC1. SST 09843–18020 4. Start the engine. 5. Check that the ABS warning light blinks HINT: If the ABS warning light does not blink, inspect the ABS warning light circuit (See page BR–177j. 6. Drive vehicle straight forward. HINT: • Drive vehicle at 45–55 km/h (28–34 mph) for several seconds. • If the brake is applied during the check, the check routine must be started again. 7. Stop the vehicle. 8. Turn the ignition switch to OFF. 9. Disconnect terminals Ts and E1, and connect Te and E1. 10. Turn the ignition switch to ON. 11. Read the number of blinks of the ABS warning light. HINT: See the list of diagnostic trouble codes shown on the next page. If every sensor is normal, a normal code is output (A cycle of 0.25 sec. ON and 0.25 sec. OFF is repeated). If 2 or more malfunctions are indicated at the same time, the lowest numbered code will be displayed first. 12. After performing the check, disconnect terminals Tc and E1 of DLC1, and ignition switch turned off. BR–315 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Perform steps 1.  7. on the previous page. 2. Hook up the Toyota hand–held tester to the DLC2. 3. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the Toyota hand–held tester operator’s manual for further details. Diagnostic Trouble Code of Speed Sensor Check Function Code No. Trouble Area Diagnosis Low output voltage of right front speed sensor • • Right front speed sensor Sensor installation Low output voltage of left front speed sensor • • Left front speed sensor Sensor installation Low output voltage of right rear speed sensor • • Right rear speed sensor Sensor installation Low output voltage of left rear speed sensor • • Left rear speed sensor Sensor installation Abnormal change in output voltage of right front speed sensor • Right front speed sensor rotor Abnormal change in output voltage of left front speed sensor • Left front speed sensor rotor Abnormal change in output voltage of right rear speed sensor • Right rear speed sensor rotor Abnormal change in output voltage of left rear speed sensor • Left rear speed sensor rotor BR–316 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) PROBLEM SYMPTOMS CHART If a normal code is displayed during the diagnostic trouble code check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. Inspection Circuit Symptoms ABS does not operate. ABS does not operate efficiently. Only when 1.  4. are all normal and the problem is still occurring, replace the ABS ECU. 1. Check the diagnostic trouble code, reconfirming that the normal code is output. 2. IG power source circuit. 3. Speed sensor circuit. 4. Check the hydraulic circuit for leakage. Only when 1. 4. are all normal and the problem is still occurring, replace the ABS ECU. 1. Check the diagnostic trouble code, reconfirming that the normal code is output. 2. Speed sensor circuit. 3. Stop light switch circuit. 4. Check the hydraulic circuit for leakage. ABS warning light abnormal. 1. ABS warning light circuit. 2. ABS ECU. Diagnostic trouble code check cannot be performed. Only when 1. and 2. are all normal and the problem is still occurring, replace the ABS ECU. 1. ABS warning light circuit. 2. Tc terminal circuit. Speed sensor signal check cannot be performed. See page BR–143 BR–170 BR–166 BR–185 BR–143 BR–166 BR–175 BR–185 BR–177 BR–177 BR–180 BR–183 1. Ts terminal circuit. 2. ABS ECU. BR–317 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) LOCATION OF CONNECTORS Location of Connectors in Engine Compartment 1M2–FE Engine: BR–318 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–319 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in Engine Compartment 5S–FE Engine: BR–320 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–321 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Location of Connectors in instrument Panel BR–322 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–323 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–324 BRAKE SYSTEM – J/B No. 1 ANTI–LOCK BRAKE SYSTEM (ABS) BR–325 BRAKE SYSTEM Location of Connectors in Body Sedan: Coupe: – ANTI–LOCK BRAKE SYSTEM (ABS) BR–326 BRAKE SYSTEM Wagon: – ANTI–LOCK BRAKE SYSTEM (ABS) BR–327 BRAKE SYSTEM –MEMO– – ANTI–LOCK BRAKE SYSTEM (ABS) BR–328 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) CIRCUIT INSPECTION DTC 11,13 ABS Solenoid and Motor Relay Circuit CIRCUIT DESCRIPTION The solenoid relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay goes on. The motor relay supplies power to the ABS pump motor. While the ABS is activated, the ECU switches the motor relay ON and operates the ABS pump motor. DTC No. Diagnostic Trouble Code Detecting Condition Trouble area (1) 5V is applied to the solenoid voltage monitor terminal (AST) for 30 sec. or more, with the IG switch ON and the warning light on. (2) 5V is applied to the solenoid voltage monitor terminal (AST) for 0.02 sec. or more, after the warning light goes off. • • Open or short in ABS solenoid relay circuit. ECU. (1) The motor voltage monitor terminal (MT) is ON for 5 sec. or more, with the motor relay operation signal OFF. (2) The motor voltage monitor terminal (MT) is OFF for 0.04 sec. with the motor relay opera– tion signal ON. • • • Pump motor. Open in ABS motor relay circuit. ECU. Fail safe function: If trouble occurs in the control (solenoid) relay circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. DIAGNOSTIC CHART Check voltage of ABS ECU connector. Check and repair harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. HINT: When DTC13 is output, check that the pump motor ground wire is installed correctly. BR–329 BRAKE SYSTEM WIRING DIAGRAM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–330 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals connector. 1 and 4 of ABS ECU Disconnect the ABS ECU connector. Measure voltage between terminals A5 1 and A5 4 of ABS ECU harness side connector. Voltage: 10–14 V Check and repair harness or connector. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–331 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 21, 22, 23 ABS Actuator Solenoid Circuit CIRCUIT DESCRIPTION This solenoid goes on when signals are received from the ECU and controls the pressure acting on the wheel cylinders, thus controlling the braking force. DTC No. Diagnostic Trouble Code Detecting Condition Trouble area (1) OV is applied to terminal SFR for 0.035 sec. while battery voltage is applied to the sole– noid voltage monitor terminal (AST) and the ECM power transistor is OFF. (2) Battery voltage is applied to terminal SFR for 0.035 sec. while battery voltage is applied to the solenoid voltage monitor terminal (AST) and the ECM power transistor is ON. • • • ABS actuator (solenoid valve). Open or short in right front solenoid circuit. ECU. (1) OV is applied to terminal SFL for 0.035 sec. while battery voltage is applied to the sole– noid voltage monitor terminal (AST)and the ECM power transistor is OFF. (2) Battery voltage is applied to terminal SFL for 0.035 sec. while battery voltage is applied to the solenoid voltage monitor terminal (AST) and the ECM power–transistor is ON. • • • ABS actuator (solenoid valve). Open or short in left front solenoid circuit. ECU. (1) OV is applied to terminal SRA for 0.035 sec. while battery voltage is applied to the sole– noid voltage monitor terminal (AST) and the ECM power transistor is OFF. (2) Battery voltage is applied to terminal SRA for 0.035 sec. while battery voltage is applied to the solenoid voltage monitor terminal (AST) and the ECM power transistor is ON. • • • ABS actuator (solenoid valve). Open or short in rear solenoid circuit. ECU. Fail safe function; If trouble occurs in the actuator solenoid circuit, the ECU cuts off current to the solenoid relay and prohibits ABS control. Check ABS actuator solenoid. Replace ABS actuator. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–332 BRAKE SYSTEM WIRING DIAGRAM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–333 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check ABS actuator solenoid. Remove the ABS ECU cover and disconnect 6–pin connector. Check continuity between terminals 1 and 2, 3 and 4, 5 and6. Continuity HINT: Resistance of each solenoid coil is 1.1. Replace ABS actuator. If the same code is still output after the diagnostic trouble code is deleted, check the contact condition of each connection. If the connections are normal, the ECU may be defective. BR–334 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 31,32,33,34,35, 36, 38, 39 Speed Sensor Circuit CIRCUIT DESCRIPTION The speed sensor detects the wheel speed and sends the appropriate signals to the ECU. These signals are used to control the ABS system. The front and rear rotors each have 48 serrations. When the rotors rotate, the magnetic field emitted by the permanent magnet in the speed sensor generates an AC voltage. Since the frequency of this AC voltage changes in direct proportion to the speed of the rotor, the frequency is used by the ECU to detect the speed of each wheel. DTC No. 31,32, 33,34 Diagnostic Trouble Code Detecting Condition (1) No pulse is input when the vehicle speed reaches 12 km/h (7 mph). (2) No pulse is input when the vehicle speed reaches 20 km/h (12 mph). (3) When the vehicle speed is 10 km/h (7 mph) or above, a pulse is not input for at least 20 sec. Trouble area • • • • • • 35,36, 38,39 The hardware detects a constant open is each sensor circuit. • • Right front, left front, right rear and left rear speed sensor. Open in each speed sensor circuit. Sensor installation Sensor rotor ECU. Right front, left front, right rear and left rear speed sensor. Open in each speed sensor circuit. ECU. HINT: DTC Nos. 31 and 35 are for the right front speed sensor. DTC Nos. 32 and 36 are for the left front speed sensor. DTC Nos. 33 and 38 are for the right rear speed sensor DTC Nos. 34 and 39 are for the left rear speed sensor. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. BR–335 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DIAGNOSTIC CHART Check speed sensor. Replace speed sensor. Check for open and short in harness and con– nector between each speed sensor and ECU. Repair or replace harness or connector. Check sensor rotor and sensor installation. Replace speed sensor or rotor. Check and replace ABS ECU. WIRING DIAGRAM BR–336 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check speed sensor. Front 1. Remove front fender liner. 2. Disconnect speed sensor connector. Measure resistance between terminals 1 and 2 of speed sensor connector. Resistance: 0.6–1.8 k
Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. Resistance: 1 MO or higher Rear 1. Remove the seat cushion (and side seat back). 2. Disconnect speed sensor connector. Measure resistance between terminals 1 and 2 of speed sensor connector. Resistance: 0.6–1.8 tc
Measure resistance between terminals 1 and 2 of speed sensor connector and body ground. Resistance: 1 M
or higher Replace speed sensor. Check for open and short in harness and connector between each speed sensor and ECU (See page IN–28). Repair or replace harness or connector. BR–337 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check sensor rotor and sensor installation. Front Remove front drive shaft (See SA section). Check sensor rotor serrations. No scratches or missing teeth. Check the front speed sensor installation The installation bolt is tightened properly. Rear Remove the axle hub (See SA section). Check the sensor rotor serrations. No scratches or missing teeth. Check the speed sensor installation The installation bolt is tightened properly and there is no clearance between the sensor and rear axle carrier. Replace speed speed or rotor. Check and replace ABS ECU. BR–338 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 41 +BS Power Source Circuit CIRCUIT DESCRIPTION This is the power source for the ECU, hence the CPU, and the actuators. DTC No. Diagnostic Trouble Code Detecting Condition (1) Voltage of 5V or more, or 9.4V or less, is applied for at least 60 sec. to terminal +BS before the ABS primary check and ABS operation. (2) Voltage of 5V or more, or 9.4V or less, is applied to terminal +BS for 0.2 sec. or more, after the ABS primary check and before ABS operation. (3) During ABS operation, voltage of 5V or more, or 8.8V or less, is applied to terminal +BS for 0.2 sec. or more. Trouble area • • • • Battery. IC regulator. Open or short in power source circuit. ECU. Fail safe function: If trouble occurs in the power source circuit, the ECU cuts off current to the ABS solenoid relay and prohibits ABS control. If the voltage applied to terminal +BS becomes 9.9V or less, the warning light goes off and ABS control becomes possible. DIAGNOSTIC CHART Check battery positive voltage. Check and repair the charging system. Check voltage between terminals +BS and GND of ABS ECU connector. Check and replace ABS ECU. Check continuity between terminals GND of ABS ECU connector and body ground. Check ECU–IG fuse. Check for open in harness and connector between ABS ECU and battery. Repair or replace harness or connector. Check for short in all the harness and components connected to ECU–IG fuse (See attached wiring diagram). BR–339 BRAKE SYSTEM WIRING DIAGRAM – ANTI–LOCK BRAKE SYSTEM (ABS) BR–340 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check battery positive voltage. Voltage: 10–14 V Check and repair the charging system. Check voltage between terminals +BS and GND of ABS ECU connector. Disconnect ABS ECU connector. 1. Turn ignition switch ON. 2. Measure voltage between terminals IG1 and GND of ABS ECU connector. Voltage: 10–14 V Check and replace ABS ECU. Check continuity between terminal GND of ABS ECU connector and body ground. Measure resistance between terminal GND of ABS ECU connector and body ground. Resistance: 1
or less Repair or replace harness or connector. BR–341 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check ECU–IG fuse. Remove ECU–IG fuse from J/B No. 1. Check continuity of ECU–IG fuse. Continuity Check for short in. a1I the harness and components connected to ECU–IG fuse (See attached wiring diagram). Check for open in harness and connector between ABS ECU and battery (See page IN–28). BR–342 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) DTC 51 ABS Pump Motor Lock CIRCUIT DESCRIPTION DTC No. Diagnostic Trouble Code Detecting Condition Pump motor is not operating normally during initial check. Trouble area • ABS pump motor. Fail safe function: If trouble occurs in the ABS pump motor, the ECU cuts off current to the solenoid relay and prohibits ABS control. DIAGNOSTIC CHART Check that the pump motor ground wire is installed correctly. If it is OK, replace the ABS actuator assembly. BR–343 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Stop Light Switch Circuit CIRCUIT DESCRIPTION This stop light switch senses whether the brake pedal is depressed or released, and sends the signal to the ECU. DIAGNOSTIC CHART Check operation of stop light. Repair stop light circuit (See page BE– 65). Check voltage of terminal STP. Proceed to next circuit inspection shown on problem symptoms chart (See page BR–148y. Check for open in harness and connector be– tween ABS ECU and stop light switch (See page IN–27). Repair–or replace harness or connector. Check and replace ABS ECU. WIRING DIAGRAM BR–344 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check operation of stop light. Check that stop light lights up when brake pedal is depressed and turns off when brake pedal is released. Repair stop light circuit (See page BE–65). Check voltage between terminal STP of ABS ECU connector and body ground. Disconnect ABS ECU connector. Measure voltage between terminal STP and body ground. Voltage: 8–14 V Proceed to next circuit inspection shown on problem symptoms chart (See page BR–148 ). Check for open in harness and connector between ABS ECU and stop light switch (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. BR–345 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS Warning Light Circuit CIRCUIT DESCRIPTION If the ECU detects trouble, it lights the ABS warning light while at the same time prohibiting ABS control. At this time, the ECU records a diagnostic trouble code in memory. Connect terminals Tc and E1 of the DLC1 or DLC2 to make the ABS warning light to blink and output the diagnostic trouble code. DIAGNOSTIC CHART Perform troubleshooting in accordance with the chart below for each trouble symptom. ABS warning light does not light up Go to step ABS warning light remains on Go to step WIRING DIAGRAM BR–346 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) ABS warning light does not light up. Repair or replace ABS warning light bulb or circuit. Check ABS warning light. Check for–open in harness and connector–be– tween GAUGE fuse and ECU. ABS warning light remains on. Is diagnostic trouble code output? Does ABS warning light go off if short pin is removed? YES Check for short in harness and connector be– tween DLC1 and ECU terminal WB. YES Repair circuit indicated by the code output. Check for short in harness and connec– tor between warning light and DLC1, DLC2 and ECU terminal WA. BR–347 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check ABS warning light. See Combination Meter–Troubleshooting on page BE–1 18. Replace bulb or combination meter assembly. Check for open in harness and connector between GAUGE fuse and ECU (See page IN–27). Is diagnostic trouble code output? Perform diagnostic trouble code check on page BR–143. YES Repair circuit indicated by the code output. Does ABS warning light go off if short pin is removed? YES Check for short in harness and connector between warning light and DLC1, DLC2 and ECU terminal WA (See page IN–28). Check for short in harness and connector between DLC1 and ECU terminal WB (See page IN–27). BR–348 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Terminal Circuit CIRCUIT DESCRIPTION Connecting terminals Te and E1 of the DLC1 or the DLC2 causes the ECU to display the diagnostic trouble code by flasing the ABS warning light. DIAGNOSTIC CHART Check voltage between terminals Tc and El of DLC2 or DLC 1. If ABS warning light does not blink even after Tc and E1 are connected, the ECU may be defective.* Check for open and short in harness and connec– tor between ABS ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN–28). Repair or replace harness or connector. Check and replace A6S ECU. *: Provided that the harness between terminal Tc of DLC2 or DLC1 and terminal Tc of ECU is not open. BR–349 BRAKE SYSTEM WIRING DIAGRAM 1 M^–FE: 5S–FE: – ANTI–LOCK BRAKE SYSTEM (ABS) BR–350 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals Te and E1 of DLC2 or DLC1. 1. Turn ignition switch ON. 2. Measure voltage between terminals Tc and E1 of DLC2 or DLC1. Voltage: 10–14 V If ABS warning light does not blink even after Tc and E 1 are connected, the ECU may be defective. Check for open and short in harness and connector between ABS ECU and DLC2 or DLC1, DLC2 or DLC1 and body ground (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. BR–351 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Ts Terminal Circuit CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal which can not be detected with the diagnostic trouble code check. Connecting terminals Ts and E1 of the DLC1 in the engine compartment starts the check. DIAGNOSTIC CHART Check voltage between terminals Ts and E1 of DLC1. If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective. Check for open and short in harness and connec– tor between ABS ECU and DLC1, DLC1 and body ground (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. WIRING DIAGRAM BR–352 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) INSPECTION PROCEDURE Check voltage between terminals¿¿and E1 of DLC1. 1. Turn ignition switch ON. 2. Measure voltage between terminals Ts and E1 of DLC 1. Voltage: 10–14 V If ABS warning light does not blink even after Ts and E1 are connected, the ECU may be defective. Check for open and short in harness and connector between ABS ECU and DLC1, DLC1 and body ground (See page IN–28). Repair or replace harness or connector. Check and replace ABS ECU. BR–353 BRAKE SYSTEM – ANTI–LOCK BRAKE SYSTEM (ABS) Check for Fluid Leakage Check for fluid leakage from actuator or hydraulic lines. BR–354 BRAKE SYSTEM – SERVICE SPECIFICATIONS SERVICE DATA Brake pedal height (from asphalt sheet) Brake pedal freeplay Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf) Brake booster push rod to piston clearance (w/SST) Front brake pad thickness (5S–FE engine) STD Front brake pad thickness (5S–FE engine) Limit Front brake pad thickness (1 MZ–FE engine) STD Front brake pad thickness (1 MZ–FE engine) Limit Front brake disc thickness STD Front brake disc thickness Limit Front brake disc runout Limit Rear brake drum inside diameter STD Rear brake drum inside diameter Limit Rear brake shoe lining thickness STD Rear brake shoe lining thickness Limit Rear brake drum to shoe clearance Rear brake pad thickness STD Rear brake pad thickness Limit Rear brake disc thickness STD Rear brake disc thickness Limit Rear brake disc runout Limit Rear brake disc inside diameter STD Rear brake disc inside diameter Limit Parking brake lining thickness for rear disc brake STD Parking brake lining thickness for rear disc brake Limit Parking brake lever travel at 196 N (20 kgf, 44 lbf) Parking brake pedal travel at 294 N (30 kgf, 66 lbf) Parking brake clearance between rear shoe and lever Parking brake adjusting shim thickness for rear disc brake SERVICE SPECIFICATIONS CH–1 CHARGING SYSTEM – CHARGING SYSTEM CH–2 CHARGING SYSTEM – (5S–FE) (5S–FE) DESCRIPTION The generator is a small, high speed, high performance type with an voltage regulator incorporat– ed. The voltage regulator uses integrated circuits and controls the voltage produced by the generator. PRECAUTION 1. 2. 3. 4. Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running. CH–3 CHARGING SYSTEM – (5S–FE) SYSTEM CIRCUIT OPERATION EH00N–0a When the ignition switch is turned ON, current from the battery flows from terminal L of the generator through the voltage regulator to terminal E, causing the discharge warning light to light up. Then when the engine is started, the voltage output increases as the generator rpm increases. When the voltage output becomes greater than the battery voltage, current for recharging flows from terminal B. Simultaneously, voltage at terminal L increases and the potential difference between battery and terminal L disappears, causing the discharge warning light to go off. When the voltage output exceeds the regulator adjustment voltage, the transistor inside the voltage regulator regulates the voltage so that the voltage from the generator remains constant. CH–4 CHARGING SYSTEM – (5S–FE) PREPARATION SST (SPECIAL SERVICE TOOLS) 09285–76010 Injection Pump Camshaft Bearing Cone Replacer Rotor rear bearing cover 09286–46011 Injection Pump Spline Shaft Puller Rectifier end frame 09608–20012 Front Hub & Drive Pinion Bearing Tool Set (09608–00030) Replacer Rotor front bearing 09820–00021 Alternator Rear Bearing Puller 09$20–00030 Alternator Rear Bearing Replacer Rotor rear bearing 09820–63010 Alternator Pulley Set Nut Wrench Set RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set EQUIPMENT Ammeter(A) Battery specific gravity gauge Belt tension gauge Torque wrench Vernier calipers Rotor (Slip ring), Brush CH–5 CHARGING SYSTEM – (5S–FE) ON–VEHICLE INSPECTION 1. Except Delco Battery: CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. A. Maintenance Free Battery If under the lower level, replace the battery (or add distilled water if possible). Check the charging system. 6. Except Maintenance Free Battery If under the “LOWER” or “MIN” line, add distilled water. 2. Except Delco Battery: CHECK BATTERY VOLTAGE AND SPECIFIC GRAVITY A. Maintenance Free Battery Measure the battery voltage between the terminals negative (–) and positive (+) of the battery. Standard voltage: 12.7 – 12.9 V at 200C (680F) HINT: • Before measuring the voltage, turn the ignition switch to LOCK and turn off the electrical sys– tems (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. • If the vehicle has been running, wait 5 minutes or more after the vehicle stops before measuring the battery voltage. If the voltage is less than specification, charge the battery. HINT: Check the indicator as shown in the illustration. CH–6 CHARGING SYSTEM – (5S–FE) B. Except Maintenance Free Battery Check the specific gravity of each cell. Standard specific gravity: 55D23L battery for GNB Incorporated 1.25 – 1.27 at 20°C (68° F) 55D23L battery for JOHNSON CONTROLS 1.26 – 1.28 at 27°C (81°F) 80D26L battery for GNB Incorporated 1.27 – 1.29 at 20°C (68°F) 80D26L battery for JOHNSON CONTROLS 1.28 – 1.30 at 27°C (81°F) If the gravity is less than specification, charge the battery. HINT: Check the indicator as shown in the illustration. 3. Delco Battery: CHECK HYDROMETER Green Dot visible: Battery is adequately charged Dark (Green Dot not visible): Battery must be charged Clear or Light Yellow: Replace battery HINT: There is no need to add water during the entire service life of the battery. 4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES (a) Check that the battery terminals are not loose or corroded. (b) Check the fusible link and fuses for continuity. Fusible link: MAIN 2.0L H – Fuse: ALT 100A M – Fuse: AM 1 40A Fuse: AM2 30A IG2 7.5A GAUGE 10A ALT 7.5A CH–7 CHARGING SYSTEM – (5S–FE) 5. INSPECT DRIVE BELT (a) Visually check the drive belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a drive belt are consid– ered acceptable. If the drive belt has chunks missing from the ribs, it should be replaced. (b) Using a belt tension gauge, measure the belt tension. Belt tension gauge: Nippondenso BTG–20 (95506–00020) Borroughs No. BT–33–73F Drive belt tension: w/ A/C Now belt 175 ± 5 lbf Used belt 130 ± 10 lbf w/o A/C New belt 125 ± 25 lbf Used belt 95 ± 20 lbf If the belt tension is not as specified, adjust it. HINT: • ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. • ”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. • After installing a belt, check that it fits properly in the ribbed grooves. • Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. • After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. 6. VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES (a) Check that the wiring is in good condition. (b) Check that there is no abnormal noise from the gener– ator while the engine is running. CH–8 CHARGING SYSTEM – (5S–FE) 7. CHECK DISCHARGE WARNING LIGHT CIRCUIT (a) Warm up the engine and then turn it off. (b) Turn off all accessories. (c) Turn the ignition switch ’”ON’. Check that the dis– charge warning light is lit. (d) Start the engine. Check that the light goes off. If the light does not go off as specified, troubleshoot the discharge light circuit. 8. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, con– nect the tester to the charging circuit as per manufacturer ’s instructions. (a) If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows: • Disconnect the wire from terminal B of the gener– ator, and connect it to the negative (–) tester probe of the ammeter. • Connect the positive (+) tester probe of the am– meter to terminal B of the generator. • Connect the positive (+) tester probe of the volt– meter to terminal B of the generator. • Ground the negative (–) tester probe of the volt– meter. (b) Check the charging circuit as follows: With the engine running from idling to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 13.9 – 15.1 V at 25°C (77°F) 13.5 – 14.3 V at 115
C (239
F) If the voltmeter reading is more than standard voltage, replace the voltage regulator. If the voltmeter reading is less than standard voltage, check the voltage regulator and generator as follows: • With terminal F grounded, start the engine and check the voltmeter reading of terminal B. CH–9 CHARGING SYSTEM • • – (5S–FE) If the voltmeter reading is more than standard voltage, replace the voltage regulator. If the voltmeter reading is less than standard voltage, check the generator. 9. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch at ’Hl”. (b) Check the reading on the ammeter. Standard amperage: 30 A or more If the ammeter reading is less than the standard am– perage, repair the generator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage. CH–10 CHARGING SYSTEM – (5S–FE) GENERATOR COMPONENTS FOR REMOVAL AND INSTALLATION GENERATOR REMOVAL (See Components for Removal and installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE GENERATOR (a) Disconnect the wire clamp from the wire clip on the rectifier end frame. (b) Disconnect the generator connector. (c) Remove the rubber cap and nut, and disconnect the generator wire. CH–11 CHARGING SYSTEM – (5S– FE) (d) Loosen the adjusting lock bolt (w/ A/C), adjusting bolt and pivot bolt. (e) Remove the drive belt. (f) Remove the adjusting lock bolt (w/ A/C) or adjusting bolt (w/o A/C) and pivot bolt. (g) Remove the generator. CH–12 CHARGING SYSTEM – (5S–FE) COMPONENTS FOR DISASSEMBLY AND ASSEMBLY GENERATOR DISASSEMBLY (See Components for Disassembly and Assembly) 1. REMOVE REAR END COVER (a) Remove the nut and terminal insulator. (b) Remove the 3 nuts and end cover. CH–13 CHARGING SYSTEM – (5S–FE) 2. REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR (a) Remove the 5 screws, brush holder and voltage regu– lator. (b) Remove the brush holder cover from the brush holder. 3. REMOVE RECTIFIER HOLDER (a) Remove the 4 screws and rectifier holder. (b) Remove the 4 rubber insulators. 4. REMOVE PULLEY (a) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820–63010 Torque: 39 N⋅m (400 kgf⋅cm. 29 ft⋅lbf) (b) Check that SST (A) is secured to the rotor shaft. CH–14 CHARGING SYSTEM – (5S–FE) (c) Mount SST (C) in a vise. (d) Insert SST (B) into SST (C), and attach the pulley nut to SST (C). (e) To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one–half of a turn. (f) Remove the generator from SST (C). (g) Turn SST (B), and remove SST (A and B). (h) Remove the pulley nut and pulley. 5. REMOVE RECTIFIER END FRAME (a) Remove the 4 nuts and wire clip. CH–15 CHARGING SYSTEM – (5S–FE) (b) Using SST, remove the rectifier end frame. SST 09286 – 46011 (c) Using snap ring pliers, remove the generator washer from the rectifier end frame. 6. REMOVE ROTOR FROM DRIVE END FRAME GENERATOR INSPECTION AND REPAIR Rotor 1. INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: 2.8 – 3.0 Ω at 20°C (68°F) If there is no continuity, replace the rotor. 2. INSPECT ROTOR FOR GROUND Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor. CH–16 CHARGING SYSTEM – (5S–FE) 3. INSPECT SLIP RINGS (a) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. (b) Using a vernier caliper, measure the slip ring diameter. Standard diameter: 14.2 – 14.4 mm (0.559 – 0.567 in.) Minimum diameter: 12.8 mm (0.504 in.) If the diameter is less than minimum, replace the rotor. Stator (Drive End Frame) 1. INSPECT STATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly. 2. INSPECT STATOR FOR GROUND Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly. Brushes 1. INSPECT EXPOSED BRUSH LENGTH Using vernier calipers, measure the exposed brush length. Standard exposed length: 10.5 mm (0.413 In.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than minimum, replace the brushes. CH–17 CHARGING SYSTEM – (5S–FE) 2. IF NECESSARY, REPLACE BRUSHES (a) Unsolder and remove the brush and spring. (b) Run the wire of a new brush through the spring and the hole in the brush –holder, and insert the spring and brush into the brush holder. (c) Solder the brush wire to the brush holder at specified exposed length. Exposed length: 10.5 mm (0.413 in.) (d) Check that the brush moves smoothly in the brush holder. (e) Cut off the excess wire. (f) Apply insulation paint to *the soldered area. Rectifiers (Rectifier Holder) 1. INSPECT POSITIVE RECTIFIER (a) Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. (b) Reverse the polarity of the tester probes and repeat step (a). (c) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. 2. INSPECT NEGATIVE RECTIFIER (a) Using an ohmmeter, connect one tester probe to each negative (–) terminal and the other to each rectifier terminal. (b) Reverse the polarity of the tester probes and repeat step (a). (c) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. CH–18 CHARGING SYSTEM – (5S–FE) Bearings 1. INSPECT FRONT BEARING Check that the bearing is not rough or worn. 2. IF NECESSARY, REPLACE FRONT BEARING (a) Remove the 4 screws, bearing retainer and bearing. (b) Using a socket wrench and press, press out the bear– ing. (c) Using SST and a press, press in a new bearing. SST 09608–20012 (09608–00030) (d) Install the bearing retainer with the 4 screws. Torque: 2.6 N⋅m (27 kgf⋅cm, 23 in.⋅lbf) CH–19 CHARGING SYSTEM – (5S–FE) 3. INSPECT REAR BEARING Check that the bearing is not rough or worn. 4. IF NECESSARY, REPLACE REAR BEARING (a) Using SST, remove the bearing cover (outside) and bearing. SST 09820–00021 NOTICE: Be careful not to damage the fan. (b) Remove the bearing cover (inside). (c) Place the bearing cover (inside) on the rotor. (d) Using SST and a press, press in a new bearing. SST 09820–00030 (e) Using SST, push in the bearing cover (outside). SST 09285 – 76010 CH–20 CHARGING SYSTEM – (5S–FE) GENERATOR ASSEMBLY (See Components for Disassembly and Assembly) 1. PLACE RECTIFIER END FRAME ON PULLEY 2. INSTALL ROTOR TO DRIVE END FRAME 3. INSTALL RECTIFIER END FRAME (a) Insert the generator washer into the rectifier end frame. NOTICE: Be careful of the generator washer installation direction. (b) Using a 29 mm socket wrench and press, slowly press in the rectifier end frame. (c) Install the wire clip and 4 nuts. Torque: 4.5 N⋅m (46 kgf⋅cm, 40 in.⋅lbf) CH–21 CHARGING SYSTEM – (5S–FE) 4. INSTALL PULLEY (a) Install the pulley to the rotor shaft by tightening the pulley nut by hand. (b) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820 – 63010 Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) (c) Check that SST (A) is secured to the pulley shaft. (d) Mount SST (C) in a vise. (e) Insert SST (B) into SST (C), and attach the pulley nut to SST (C). (f) To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 110 N⋅m (1,125 kgf⋅cm, 81 ft⋅lbf) (g) Remove the generator from SST (C). (h) Turn SST (B), and remove SST (A and B). CH–22 CHARGING SYSTEM – (5S–FE) 5. INSTALL RECTIFIER HOLDER (a) Install the 4 rubber insulators on the lead wires. NOTICE: Be careful of the rubber insulators installation direction. (b) Install the rectifier holder while pushing it with the 4 screws. Torque: 2.0 N⋅m (20 kgf⋅cm, 17 in.⋅lbf) 6. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER (a) Install the brush holder cover to the brush holder. NOTICE: Be careful of the holder installation direction. (b) Place the voltage regulator together with the brush holder horizontally on the rectifier end frame. (c) Install the 5 screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder and voltage regulator. CH–23 CHARGING SYSTEM – (5S–FE) (d) Fit the brush holder cover. 7. INSTALL REAR END COVER (a) Install the end cover with the 3 nuts. Torque: 4.5 N⋅m (46 kgf⋅cm, 40 in.⋅lbf) (b) Install the terminal insulator with the nut. Torque: 4.1 N⋅m (42 kgf⋅cm, 36 in.⋅lbf) 8. CHECK THAT ROTOR ROTATES SMOOTHLY CH–24 CHARGING SYSTEM – (5S–FE) GENERATOR INSTALLATION (See Components for Removal and Installation) 1. INSTALL GENERATOR (a) Temporarily install the generator with the pivot bolt and adjusting lock bolt (w/ A/C) or adjusting bolt (w/o A/C). (b) Install the drive belt with the adjusting bolt. (c) Adjust the drive belt with the adjusting bolt. (See step 5 on page CH–7) (d) Tighten the pivot bolt, adjusting lock bolt (w/ A/C) and adjusting bolt (w/o A/C). Torque: Pivot bolt 52 N⋅m (530 kgf⋅cm, 38 ft⋅lbf) Adjusting lock bolt (w/ A/C) or adjusting bolt (w/o A/C) 18 N⋅m (185 kgf⋅cm, 13 ft⋅lbf) (f) Connect the generator connector. (g) Connect the generator wire with the nut and rubber cap. (h) Install the wire clamp to the wire clip on the rectifier end frame. 2. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 3. PERFORM ON–VEHICLE INSPECTION (See page CH–5) CH–25 CHARGING SYSTEM – SERVICE SPECIFICATIONS SERVICE DATA Battery (Except Delco Battery) Voltage (Maintenance free battery) Specific gravity (Except maintenance free battery) 55D23L Battery GNB Incorporated JHONSON CONTROLS 80D26L Battery GNB Incorporated JHONSON CONTROLS Drive belt Tension Generator Rated output Rotor coil resistance Slip ring diameter Brush exposed length Voltage regulator Regulating voltage TORQUE SPECIFICATIONS Part tightened Bearing cover x Drive end frame Rectifier end frame x Drive end frame Generator pulley x Rotor Rectifier holder x Coil lead on rectifier end frame Rear end cover x Rectifier holder Terminal insulator x Rectifier holder Generator x Generator bracket Generator x Adjusting bar (5S–FE) CH–26 CHARGING SYSTEM – (1MZ–FE) (1MZ–FE) DESCRIPTION The generator is a small, high–speed, high–performance type with a voltage regulator incorpo– rated. The voltage regulator uses integrated circuits and controls the voltage produced by the generator. PRECAUTION 1. 2. 3. 4. Check that the battery cables are connected to the correct terminals. Disconnect the battery cables when the battery is given a quick charge. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running. CH–27 CHARGING SYSTEM – (1MZ–FE) SYSTEM CIRCUIT OPERATION When the ignition switch is turned ON, current from the battery flows from terminal L of the generator through the voltage regulator to terminal E, causing the discharge warning light to light up. Then when the engine is started, the voltage output increases as the generator speed increases. When the voltage output becomes greater than the battery voltage, current for recharging flows from terminal B. Simultaneously, voltage at terminal L increases and the potential difference between battery and terminal L disappears, causing the discharge warning light to go off. When the voltage output exceeds the regulator adjustment voltage, the transistor inside the voltage regulator regulates the voltage so that the voltage from the generator remains constant. CH–28 CHARGING SYSTEM – (1MZ–FE) PREPARATION SST (SPECIAL SERVICE TOOLS) 09285–76010 Injection Pump Camshaft Bearing Cone Replacer Rotor rear bearing cover 09286–46011 Injection Pump Spline Shaft Puller Rectifier end frame 09808–20012 Front Hub & Drive Pinion Bearing Tool Set (09608–00030) Replacer Rotor front bearing 09820–00021 Alternator Rear Bearing Puller 09820–00030 Alternator Rear Bearing Replacer Rotor rear bearing 09620–63010 Alternator Pulley Set Nut Wrench Set RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set EQUIPMENT Ammeter(A) Battery specific gravity gauge Except maintenance free battery Belt tension gauge Torque wrench Vernier calipers Rotor (Slip ring) CH–29 CHARGING SYSTEM – (1MZ–FE) ON–VEHICLE INSPECTION 1. Except Delco Battery: CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. A. Maintenance Free Battery If under the lower level, replace the battery (or add distilled water if possible). Check the charging system. B. Except Maintenance Free Battery If under the “LOWER” or ’MIN” line, add distilled water. 2. Except Delco Battery: CHECK BATTERY VOLTAGE AND SPECIFIC GRAVITY A. Maintenance Free Battery Measure the battery voltage between the terminals negative (–) and positive (+) of the battery. Standard voltage: 12.7 – 12.9 V at 20°C (68°F) HINT: • Before measuring the voltage, turn the ignition switch to LOCK and turn off the electrical sys– tems (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. • If the vehicle has been running, wait 5 minutes or more after the vehicle stops before measuring the battery voltage. If the voltage is less than specification, charge the battery. HINT: Check the indicator as shown in the illustration. CH–30 CHARGING SYSTEM – (1MZ–FE) B. Except Maintenance Free Battery Check the specific gravity of each cell. Standard specific gravity: SSD23L battery for GNB Incorporated 1.25 – 1.27 at 20°C (68°F) 55D23L battery for JOHNSON CONTROLS 1.28 – 1.28 at 27°C (81°F) 80D26L battery for GNB Incorporated 1.27 – 1.29 at 20°C (68°F) 80D28L battery for JOHNSON CONTROLS 1.28 – 1.30 at 27°C (81°F) If the gravity is less than specification, charge the battery. HINT: Check the indicator as shown in the illustration. 3. Delco Battery: CHECK HYDROMETER Green Dot visible: Battery I: adequately charged Dark (Green Dot not visible): Battery must be charged Clear or Light Yellow: Replace battery HINT: There is no need to add water during the entire service life of the battery. 4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES (a) Check that the battery terminals are not loose or corroded. (b) Check the fusible link and fuses for continuity. Fusible link: MAIN 2.0L H–fuse: ALT 100A M – fuse: AM 1 40A Fuse: AM2 30 A IG2 7.5A GAUGE 10A ALT 7.5A CH–31 CHARGING SYSTEM – (1MZ–FE) 5. INSPECT DRIVE BELT (a) Visually check the belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced. (b) Using a belt tension gauge, measure the drive belt tension. Belt tension gauge: Nippondenso BTG–20 (95506–00020) Borroughs No.BT–33 – 73F Drive belt tension: New belt 175 ± 5 lbf Used belt 115 ± 20 lbf If the belt tension is not as specified, adjust it. HINT: • ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. • ”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. • After installing a belt, check that it fits properly in the ribbed grooves. • Check with your hand to confirm that the belt has not slip out of the groove on the bottom of the pulley. • After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. 6. VISUALLY CHECK GENERATOR WIRING AND LISTEN FOR ABNORMAL NOISES (a) Check that the wiring is in good condition. (b) Check that there is no abnormal noise from the gener– ator while the engine is running. CH–32 CHARGING SYSTEM – (1MZ–FE) 7. CHECK DISCHARGE WARNING LIGHT CIRCUIT (a) Warm up the engine and then turn it off. (b) Turn off all accessories. (c) Turn the ignition switch ’ON”. Check that the dis– charge warning light is lit. (d) Start the engine. Check that the light goes off. If the light does not go off as specified, troubleshoot the discharge light circuit. 8. INSPECT CHARGING CIRCUIT WITHOUT LOAD HINT: If a battery/generator tester is available, con– nect the tester to the charging circuit as per the manufacturer ’s instructions. (a) If a tester is not available, connect a voltmeter and ammeter to the charging circuit as follows: • Disconnect the wire from terminal B of the gener– ator, and connect it to the negative (–) probe of the ammeter. • Connect the positive (+) probe of the ammeter to terminal B of the generator. • Connect the positive (+) probe of the voltmeter to terminal B of the generator. • Ground the negative (–) probe of the voltmeter. (b) Check the charging circuit as follows: With the engine running from idling to 2,000 rpm, check the reading on the ammeter and voltmeter. Standard amperage: 10 A or less Standard voltage: 14.0 – 15.0 V at 25°C (77°F) 13.5 – 14.3 V at 115°C (239°F) If the voltmeter reading is more than standard voltage, replace the voltage regulator. If the voltmeter reading is less than standard voltage, check the voltage regulator and generator as follows: • With terminal F grounded, start the engine and check the voltmeter reading of terminal6. CH–33 CHARGING SYSTEM – (1MZ–FE) If the voltmeter reading is more than standard voltage, replace the voltage regulator. If the voltmeter reading is less than standard voltage, check the generator. 9. INSPECT CHARGING CIRCUIT WITH LOAD (a) With the engine running at 2,000 rpm, turn on the high beam headlights and place the heater blower switch –at “HI”. (b) Check the reading on ’the ammeter. Standard amperage: 30 A or more If the ammeter reading is less than the standard am– perage, repair the generator. HINT: If the battery is fully charged, the indication will sometimes be less than standard amperage. CH–34 CHARGING SYSTEM – (1MZ–FE) GENERATOR COMPONENTS FOR REMOVAL AND INSTALLATION GENERATOR REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE DRIVE BELT Loosen the pivot bolt, adjusting lock bolt, and adjusting bolt, and remove the drive belt. CH–35 CHARGING SYSTEM – (1MZ–FE) 3. REMOVE GENERATOR (a) Disconnect the generator connector. (b) Remove the nut, and disconnect the generator wire. (c) Disconnect the wire harness from the clip. (d) Remove the pivot bolt, plate washer, adjusting lock bolt and generator. COMPONENTS FOR DISASSEMBLY AND ASSEMBLY CH–36 CHARGING SYSTEM – (1MZ–FE) GENERATOR DISASSEMBLY (See Components for Disassembly and Assembly) 1. REMOVE REAR END COVER (a) Remove the nut and terminal insulator. (b) Remove the screw, 3 nuts, plate terminal and end cover. 2. REMOVE BRUSH HOLDER AND VOLTAGE REGULA– TOR (a) Remove the brush holder cover from the brush holder. (b) Remove the 5 screws, brush holder and voltage regu– lator. 3. REMOVE RECTIFIER HOLDER (a) Remove the 4 screws and rectifier holder. CH–37 CHARGING SYSTEM – (1MZ–FE) (b) Remove the 4 rubber insulators. (c) Remove the seal plate. 4. REMOVE PULLEY (a) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820–63010 Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) (b) Check that SST (A) is secured to the rotor shaft. (c) Mount SST (C) in a vise. (d) Insert SST (B) into SST (C), and attach the pulley nut to SST (C). (e) To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTICE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one–half of a turn. (f) Remove the generator from SST (C). CH–38 CHARGING SYSTEM – (1MZ–FE) (g) Turn SST (B), and remove SST (A and B). (h) Remove the pulley nut and pulley. 6. REMOVE RECTIFIER END FRAME (a) Remove the 4 nuts and cord clip. (b) Using SST, remove the rectifier end frame. SST 09286–46011 (c) Remove the thrust washer. CH–39 CHARGING SYSTEM – (1MZ–FE) 6. REMOVE ROTOR FROM DRIVE END FRAME GENERATOR INSPECTION AND REPAIR Rotor 1. INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance: 2.8–3.0 Ω at 20°C (68°F) If there is no continuity, replace the rotor. 2. INSPECT ROTOR FOR GROUND Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor. 3. INSPECT SLIP RINGS (a) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. (b) Using a vernier caliper, measure the slip ring diameter. Standard diameter: 14.2–14.4 mm (0.559–0.587 In.) Minimum diameter: 12.8 mm (0.504 In.) If the diameter is less than minimum, replace the rotor. Stator (Drive End Frame) 1. INSPECT STATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly. CH–40 CHARGING SYSTEM – (1MZ–FE) 2. INSPECT STATOR FOR GROUND Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly. Brushes 1. INSPECT EXPOSED BRUSH LENGTH Using a vernier caliper, measure the exposed brush length. Standard exposed length: 10.5 mm (0.413 In.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than minimum, replace the brushes and brush holder assembly. Rectifiers (Rectifier Holder) 1. INSPECT POSITIVE RECTIFIER (a) Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. (b) Reverse the polarity of the tester probes and repeat step (a). (c) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. CH–41 CHARGING SYSTEM – (1MZ–FE) 2. INSPECT NEGATIVE RECTIFIER (a) Using an ohmmeter, connect one tester probe to each negative (–) terminal and the other to each rectifier terminal. (b) Reverse the polarity of the tester probes and repeat step (a). (c) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. Bearings 1. INSPECT FRONT BEARING Check that the bearing is not rough or worn. 2. IF NECESSARY, REPLACE FRONT BEARING (a) Remove the 4 screws, bearing retainer and bearing. (b) Using a socket wrench and press, press out the bear– ing. (c) Using SST and a press, press in a new bearing. SST 09608 – 20012 (09608 – 00030) CH–42 CHARGING SYSTEM – (1MZ–FE) (d) Install the bearing retainer with the 4 screws. 3. INSPECT REAR BEARING Check that the bearing is not rough or worn. 4. IF NECESSARY, REPLACE REAR BEARING (a) Using SST, remove the bearing cover (outside) and bearing. SST 09820–00021 NOTICE: Be careful not to damage the fan. (b) Remove the bearing cover (inside). (c) Place the bearing cover (inside) on the rotor. (d) Using SST and a press, press in a new bearing. SST 09820–00030 CH–43 CHARGING SYSTEM – (1MZ–FE) (e) Using SST, push in the bearing cover (outside). SST 09285 – 76010 GENERATOR ASSEMBLY (See Components for Disassembly and Assembly) 1. INSTALL ROTOR TO DRIVE END FRAME (a) Place the rectifier end frame on the pulley. (b) Install the rotor to the rectifier end frame. 2. INSTALL RECTIFIER END FRAME (a) Place the thrust washer on the rotor. (b) Using a 29 mm socket wrench and press, slowly press in the rectifier end frame. (c) Install the 3 nuts. Torque: 4.5 N⋅m (46 kgf⋅cm, 40 in.⋅Ibf) (d) Install the cord clip with the nut. Torque: 5.4 N⋅m (55 kgf⋅cm. 48 in.⋅lbf) CH–44 CHARGING SYSTEM – (1MZ–FE) 3. INSTALL PULLEY (a) Install the pulley to the rotor shaft by tightening the pulley nut by hand. (b) Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque. SST 09820 – 63010 Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) (c) Check that SST (A) is secured to the pulley shaft. (d) Mount SST (C) in a vise. (e) Insert SST (B) into SST (C), and attach the pulley nut to SST (C). (f) To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 110 N⋅m (1,125 kgf⋅cm, 81 ft⋅lbf) (g) Remove the generator from SST (C). (h) Turn SST (B), and remove SST (A and B). CH–45 CHARGING SYSTEM – (1MZ–FE) 4. INSTALL RECTIFIER HOLDER (a) Place the seal plate on the rectifier end frame. (b) Install the 4 rubber insulators on the lead wires. (c) Install the rectifier holder with the 4 screws. Torque: 2.94 N⋅m (30 kgf⋅cm, 26 In.⋅Ibf) 5. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER (a) Place the voltage regulator and brush holder on the rectifier end frame. NOTICE: Be careful of the holder installation direction. (b) Install the 5 screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder and connector. (c) Place the brush holder cover on the brush holder. CH–46 CHARGING SYSTEM – (1MZ–FE) 6. INSTALL REAR END COVER (a) Install the end cover and plate terminal with the 3 nuts and screw. Torque: 3.85 N⋅m (39 kgf⋅cm, 34 in.⋅lbf) for screw 4.4 N⋅m (45 kgf⋅cm, 39 in.⋅Ibf) for nut (b) Install the terminal insulator with the nut. Torque: 4.1 N⋅m (41.5 kgf⋅cm. 36 in.⋅lbf) 7. CHECK THAT ROTOR ROTATES SMOOTHLY CH–47 CHARGING SYSTEM – (1MZ–FE) GENERATOR INSTALLATION (See Components for Removal and Installation) 1. INSTALL GENERATOR (a) Mount generator on the generator bracket with the pivot bolt and adjusting lock bolt. Do not tighten the bolts yet. (b) Connect the generator connector. (c) Connect the generator wire with the nut. 2. INSTALL DRIVE BELT (a) Install the drive belt with the adjusting bolt. (b) Using a belt tension gauge, measure the drive belt tension. Belt tension gauge: Nippondenso BTG–20 (95506–00020) Borroughs No. BT–33–73F Drive belt tension: New belt 175 ± 5 lbf Used belt 115 ± 20 lbf (c) Tighten the pivot bolt and adjusting lock bolt. Torque: 56 N⋅m (570 kgf⋅cm. 41 ft⋅lbf) for pivot bolt 18 N⋅m (180 kgf⋅cm. 13 ft⋅lbf) for lock bolt HINT: • • • • • ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. ”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. After installing a belt, check that it fits properly in the ribbed grooves. Check by hand to confirm that the belt has not slip out of the groove on the bottom of the pulley. After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. 3. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 4. PERFORM ON–VEHICLE INSPECTION (See steps 7 to 9 on pages CH–32 and 33) CH–48 CHARGING SYSTEM – SERVICE SPECIFICATIONS SERVICE DATA Battery (Except Delco Battery) Voltage (Maintenance free battery) Specific gravity (Except maintenance free battery) 55D23L Battery GNB Incorporated JHONSON CONTROLS 8OD26L Battery GNB Incorporated JHONSON CONTROLS Drive belt Tension New belt Used belt Generator Rated output Rotor coil resistance Slip ring diameter Brush exposed length Voltage regulator Regulating voltage TORQUE SPECIFICATIONS Part tightened Rectifier end frame x Drive end frame Cord clamp x Rectifier end frame Generator pulley x Rotor Rectifier holder x Coil lead on rectifier end frame Rear end cover x Rectifier holder Plate terminal x Rectifier holder Terminal insulator x Rectifier holder Generator x Generator bracket Generator x Adjusting bar (1MZ–FE) CL–1 CLUTCH – CLUTCH CL–2 CLUTCH – DESCRIPTION DESCRIPTION The diaphragm spring turnover type clutch providing lighter release performance. CL–3 CLUTCH – PREPARATION PREPARATION SST(SPECIAL SERVICE TOOLS) 09023–00100 Union Nut Wrench 10 mm 09301–00210 Clutch Guide Tool 09333–00013 Clutch Diaphragm Spring Aligner RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set 09905–00013 Snap Ring Pliers EQUIPMENT Calipers Dial indicator Torque wrench Clutch line tube Clutch grabs/chatters Clutch pedal spongy Clutch noisy Clutch slips Clutch does not disengage CL–8 CL–11 CL–14 MX–33 CL–14 CL–14 CL–14 CL–14 CL–14 CL–14 CL–14 CL–14 CL–16 CL–14 CL–16 CL–14 Master cylinder cup (Damaged) Release cylinder cup (Damaged) Engine mounting (Loosen) Release bearing (Worn, dirty or damaged) Input shaft bearing (Worn or damaged) Clutch disc (Out of true) Clutch disc (Runout is excessive) Clutch disc (Lining broken) Clutch disc (Dirty or burred) Clutch disc (Oily) Clutch disc (Worn out) Clutch disc torsion rubber (Damaged) Clutch disc (Harden) Clutch disc (Lack of spline grease) Diaphragm spring (Damaged) Diaphragm spring (Out of tip alignment) Pressure plate (Distortion) CLUTCH – Flywheel (Distortion) CL–5 Trouble Clutch line (Air in line) Parts Name CL–6 See Page Clutch pedal (Freeplay out of adjustment) CL–4 TROUBLESHOOTING TROUBLESHOOTING Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. CL–5 CLUTCH – CLUTCH SYSTEM BLEEDING CLUTCH SYSTEM BLEEDING HINT: If any work is done on the clutch system or if air is suspected in the clutch lines, bleed the system of air. NOTICE: Do not let brake fluid remain on a painted sur– face. Wash it off immediately. 1. FILL CLUTCH RESERVOIR WITH BRAKE FLUID 2. CONNECT VINYL TUBE TO BLEEDER PLUG Insert the other end of the tube in a half–full contain– er of brake fluid. HINT: Check the reservoir frequently. Add fluid if necessary. 3. BLEED CLUTCH LINE (a) Slowly pump the clutch pedal several times. (b) While pressing on the pedal, loosen the bleeder plug until the fluid starts to run out. Then close the bleeder plug. SST 09023–00100 (c) Repeat this procedure until there are no more air bubbles in the fluid. CL–6 CLUTCH – CLUTCH PEDAL CLUTCH PEDAL CLUTCH PEDAL CHECK AND ADJUSTMENT 1. CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height from asphalt sheet: 160.8–170.8 mm (6.33–6.72 in.) 2. IF NECESSARY, ADJUST PEDAL HEIGHT Loosen the lock nut and turn the stopper bolt until the height is correct. Tighten the lock nut. 3. CHECK THAT PEDAL FREEPLAY AND PUSH ROD PLAY ARE CORRECT Pedal freeplay: Push in on the pedal until the beginning of clutch resistance is felt. Pedal fresplay: 5.0–15.0 mm (0.197–0.591 in.) Push rod play: Push in on the pedal with a finger softly until the resistance begins to increase a little. Push rod play at pedal top: 1.0–5.0 mm (0.039–0.197 in.) 4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND PUSH ROD PLAY (a) Loosen the lock nut and turn the push rod until the freeplay and push rod play are correct. (b) Tighten the lock nut. (c) After adjusting the pedal freeplay, check the pedal height. (d) Connect the air duct and install the lower finish panel. CL–7 CLUTCH – CLUTCH PEDAL 5. INSPECT CLUTCH RELEASE POINT (a) Pull the parking brake lever and install wheel stopper. (b) Start the engine and idle the engine. (c) Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears con– tact. (d) Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise stops (release point) up to the full stroke end position. Standard distance: 25 mm (0.98 in.) or more (From pedal stroke end position to release point) If the distance not as specified, perform the following operation. • Inspect pedal height. • Inspect push rod play and pedal freeplay. • Bleed the clutch line. • Inspect the clutch cover and disc. 6. CHECK CLUTCH START SYSTEM (a) Check that the engine does not start when the clutch pedal is released. (b) Check that the engine starts when the clutch pedal is fully depressed. If necessary, adjust or replace the clutch start switch. 7. CHECK CONTINUITY OF CLUTCH START SWITCH (a) Check that there is continuity between terminals when the switch is ON (pushed). (b) Check that there is no continuity between terminals when the switch is OFF (free). If continuity is not as specified, replace the switch. CL–8 CLUTCH – CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER COMPONENTS MASTER CYLINDER REMOVAL 1. DRAW OUT FLUID WITH SYRINGE 2. DISCONNECT CLUTCH LINE TUBE Using SST, disconnect the clutch line tube. Use a container to catch the brake fluid. SST 09023–00100 3. REMOVE CLIP AND CLEVIS PIN 4. REMOVE 2 MOUNTING NUTS AND PULL OUT MASTER CYLINDER MASTER CYLINDER DISASSEMBLY 1. REMOVE RESERVOIR TANK (a) Using a pin punch and a hammer, drive out the slotted spring pin. (b) Remove the reservoir tank and grommet. CL–9 CLUTCH – CLUTCH MASTER CYLINDER 2. REMOVE PUSH ROD Pull back the boot, and using snap ring pliers, remove the snap ring. 3. REMOVE PISTON MASTER CYLINDER INSPECTION HINT: Clean the disassembled parts with compressed air. 1. INSPECT MASTER CYLINDER BORE FOR SCORING OR CORROSION If a problem is found, clean or replace the cylinder. 2. INSPECT PISTON AND CUPS FOR WEAR, SCORING, CRACKS OR SWELLING If either one requires replacement, use the parts from the cylinder kit. 3. INSPECT PUSH ROD FOR WEAR OR DAMAGE If necessary, replace the push rod. MASTER CYLINDER ASSEMBLY 1. COAT PARTS WITH LITHIUM SOAP BASE GLYCOL GREASE. AS SHOWN 2. INSERT PISTON INTO CYLINDER 3. INSTALL PUSH ROD ASSEMBLY WITH SNAP RING 4. INSTALL RESERVOIR TANK (a) Install the reservoir tank and new grommet. (b) Using a pin punch and a hammer, drive in the slotted spring pin. CL–10 CLUTCH – CLUTCH MASTER CYLINDER MASTER CYLINDER INSTALLATION 1. INSTALL MASTER CYLINDER Install the 2 mounting nuts, and torque them. Torque: 7.8 N–m (80 kgf–cm, 58 in,.lbf) 2. CONNECT CLUTCH LINE TUBE Using SST, connect the clutch line tube. SST 09023–00100 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 3. CONNECT PUSH ROD AND INSTALL PIN Install the clip in the push rod pin. 4. BLEED SYSTEM AND ADJUST CLUTCH PEDAL (See page CL–5,6) CL–11 CLUTCH – CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER COMPONENTS RELEASE CYLINDER REMOVAL 1. DISCONNECT CLUTCH LINE TUBE Using SST, disconnect the tube. Use a container to catch the brake fluid. SST 09023–00100 2. REMOVE 2 BOLTS AND PULL OUT RELEASE CYLINDER RELEASE CYLINDER DISASSEMBLY 1. REMOVE UNION FROM RELEASE CYLINDER Remove the union bolt, 2 gaskets and union from the release cylinder. CL–12 CLUTCH – CLUTCH RELEASE CYLINDER 2. PULL OUT BOOT WITH PUSH ROD 3. REMOVE PISTON Using compressed air, remove the piston with the spring from the cylinder. RELEASE CYLINDER INSPECTION HINT: Clean the disassembled parts with compressed air. 1. INSPECT RELEASE CYLINDER BORE FOR SCORING OR CORROSION If a problem is found, clean or replace the cylinder. 2. INSPECT PISTON AND CUPS FOR WEAR, SCORING, CRACKS OR SWELLING If either one requires replacement, use the parts from the cylinder kit. 3. INSPECT PUSH ROD FOR WEAR OR DAMAGE If necessary, replace the push rod. RELEASE CYLINDER ASSEMBLY 1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN 2. INSTALL PISTON WITH SPRING INTO CYLINDER 3. INSTALL BOOT WITH PUSH ROD TO CYLINDER 4. INSTALL UNION TO RELEASE CYLINDER (a) Adjust the center line of the union is in parallel with the release cylinder. (b) Install the union bolt. Torque: 25 N–m (250 kgf–cm, 18 ft–lbf) CL–13 CLUTCH – CLUTCH RELEASE CYLINDER RELEASE CYLINDER INSTALLATION 1. INSTALL RELEASE CYLINDER WITH 2 BOLTS Torque: 13 N–m (130 kgf–cm. 9 ft–lbf) 2. CONNECT CLUTCH LINE TUBE Using SST, connect the tube. SST 09023–00100 Torque: 15 N–m (155 kgf–cm, 11 ft–lbf) 3. FILL CLUTCH RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM (See page CL–5) 4. CHECK FOR LEAKS CL–14 CLUTCH – CLUTCH UNIT CLUTCH UNIT COMPONENTS CLUTCH UNIT REMOVAL 1. REMOVE TRANSAXLE FROM ENGINE (See page MX–10) 2. REMOVE CLUTCH COVER AND DISC (a) Place matchmarks on the flywheel and clutch cover. (b) Loosen each set bolt one turn at a time until spring tension is released. (c) Remove the set bolts, and pull off the clutch cover with the clutch disc. NOTICE: Do not drop the clutch disc. CL–15 CLUTCH – CLUTCH UNIT 3. REMOVE RELEASE BEARING AND FORK FROM TRANSAXLE (a) Remove the release bearing together with the fork and then separate them. (b) Remove the boot. CLUTCH PARTS INSPECTION 1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE Using calipers, measure the rivet head depth. Minimum rivet depth: 0.3 mm (0.0121n.) If a problem is found, replace the clutch disc. 2. INSPECT CLUTCH DISC RUNOUT Using a dial indicator, check the disc runout. Maximum runout: 0.8 mm (0.031 in.) If runout is excessive, replace the clutch disc. 3. INSPECT FLYWHEEL RUNOUT Using a dial indicator, check the flywheel runout. Maximum runout: 0.1 mm (0.004 in.) If runout is excessive, replace the flywheel. 4. INSPECT DIAPHRAGM SPRING FOR WEAR Using calipers, measure the diaphragm spring for depth and width of wear. Maximum: A: Depth 0.6 mm (0.024 in.) B: Width 5.0 mm 10.197 In.) If necessary, replace the clutch cover. CL–16 CLUTCH – CLUTCH UNIT 5. INSPECT RELEASE BEARING Turn the bearing by hand while applying force in the axial direction. HINT: The bearing is permanently lubricated and re– quires no cleaning or lubrication. If a problem is found, replace the bearing. CLUTCH UNIT INSTALLATION 1. INSTALL CLUTCH DISC AND CLUTCH COVER ON FLYWHEEL (a) Insert the SST in the clutch disc, and then set them and the clutch cover in position. SST 09301–00210 (b) Align the matchmarks on the clutch cover and fly– wheel. (c) Temporarily tighten the topmost bolt from the 3 near the knock pins. HINT: Temporarily tighten the No.3 bolt. (d) Torque the bolts on the clutch cover in the order shown. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) 2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT Using a dial indicator with roller instrument, check the diaphragm spring tip alignment. Maximum non–alignment: 0.5 mm (0.020 in.) If alignment is not as specified, using SST, adjust the diaphragm spring tip alignment. SST 09333–00013 CL–17 CLUTCH – CLUTCH UNIT 3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE (NLGI NO.2) TO FOLLOWING PARTS • Release fork and hub contact point • Release fork and push rod contact point • Release fork pivot point • Clutch disc spline 4. INSTALL RELEASE BEARING AND FORK TO TRANSAXLE Install the bearing to the release fork, and then install them to the transaxle. 5. INSTALL TRANSAXLE TO ENGINE (See page MX–15) CL–18 CLUTCH SERVICE SPECIFICATIONS SERVICE DATA Pedal height from asphalt sheet Push rod play at pedal top Pedal freeplay Clutch release point from pedal full stroke end position Disc rivet head depth (Minimum) Disc runout (Maximum) Diaphragm spring tip non–alignment (Maximum) Diaphragm spring finger wear (Maximum depth) Diaphragm spring finger wear (Maximum width) Flywheel runout (Maximum) TORQUE SPECIFICATIONS Part tightened Master cylinder installation nut Release cylinder installation nut Union bolt Clutch line union Bleeder plug Release fork support Clutch cover x Flywheel Flywheel set bolt – SERVICE SPECIFICATIONS EG1–1 5S–FE ENGINE – 5S–FE ENGINE EG1–2 5S–FE ENGINE – ENGINE MECHANICAL ENGINE MECHANICAL DESCRIPTION The 5S–FE engine is an in–line, 4–cylinder, 2.2 liter DOHC 16–valve engine. EG1–3 5S–FE ENGINE – ENGINE MECHANICAL The 5S–FE engine is an in–line, 4–cylinder engine with the cylinders numbered 1–2–3–4 from the front. The crankshaft is supported by five bearings inside the crankcase. These bearings are made of aluminum alloy. The crankshaft is integrated with eight weights for balance. Oil holes are placed in the center of the crankshaft to supply oil to the connecting rods, bearing, pistons and other components. The firing order is 1–3–4–2. The cylinder head is made of aluminum alloy, with a cross flow type intake and exhaust layout and with pent–roof type combustion chambers. The spark plugs are located in the center of the combustion chambers. The intake manifold has four independent long ports and utilizes the inertial supercharging effect to improve engine torque at low and medium speeds. Exhaust and intake valves are equipped with irregular pitch springs made of special valve spring carbon steel which are capable of functioning no matter what the engine speed. The intake camshaft is driven by a timing belt, and a gear on the intake camshaft engages with a gear on the exhaust camshaft to drive it. The cam journal is supported at five places between the valve lifters of each cylinder and on the front end of the cylinder head. Lubrication of the cam journals and gears is accomplished by oil being supplied through the oiler port in the center of the camshaft. Adjustment of the valve clearance is done by means of an outer shim type system, in which valve adjusting shims are located above the valve lifters. This permits replacement of the shims without removal of the camshafts. Pistons are made of high temperature–resistant aluminum alloy, and a depression is built into the piston head to prevent interference with the valves. Piston pins are the full–floating type, with the pins fastened to neither the piston boss nor the connecting rods. Instead, snap rings are fitted on both ends of the pins, preventing the pins from falling out. The No.1 compression ring is made of steel and the No.2 compression ring is made of cast iron. The oil ring is made of a combination of steel and stainless steel. The outer diameter of each piston ring is slightly larger than the diameter of the piston and the flexibility of the rings allows them to hug the cylinder walls when they are mounted on the piston. Compression rings No.1 and No.2 work to prevent gas leakage from the cylinder and the oil ring works to scrape oil off the cylinder walls to prevent it from entering the combustion chambers. The cylinder block is made of cast iron. It has four cylinders which are approximately twice the length of the piston stroke. The top of each cylinder is closed off by the cylinder head and the lower end of the cylinders becomes the crankcase, in which the crankshaft is installed. In addition, the cylinder block contains a water jacket, through which coolant is pumped to cool the cylinders. The oil pan is bolted onto the bottom of the cylinder block. The oil pan is an oil reservoir made of pressed sheet steel. A dividing plate is included ’inside the oil pan to keep sufficient oil in the bottom of the pan even when the vehicle is tilted. This dividing plate also prevents the oil from making waves when the vehicle is stopped suddenly and the oil shifts away from the oil pump suction pipe. The 5S–FE engine uses two balance shafts. The balance shafts are fitted in balance shaft housings that are located at the bottom of the cylinder block. The No. 1 balance shaft is driven by the drive gear of the crankshaft No.3 counterweight at twice the speed of the crankshaft. The No. 2 balance shaft is driven by the No–1 balance shaft at the same speed in the same direction as the crankshaft. The balance shafts are designed to eliminate secondary inertia force from the engine, thereby reducing the engine noise (booming noise). EG1–4 5S–FE ENGINE – ENGINE MECHANICAL PREPARATION SST (SPECIAL SERVICE TOOLS) 09011–38121 12 mm Socket wrench for 12 Pointed Head Cylinder head bolt and connecting rod bolt 09201–41020 Valve Stem Oil Seal Replacer 09201–70010 Valve Guide Bushing Remover & Replacer 09202–70010 Valve Spring Compressor 09213–54015 Crankshaft Pulley Holding Tool (91651 –60855) Bolt 09213–80017 Crankshaft Pulley & Gear Puller Set (09213–00020) Body With Bolt (09213–00030) Handle (09213–00060) Bolt set 09222–30010 Connecting Rod Bushing Remover & Replacer 09223–46011 Crankshaft Front Oil Seal Replacer 09223–63010 Crankshaft Rear Oil Seal Replacer Camshaft oil seal EG1–5 5S–FE ENGINE – ENGINE MECHANICAL 09224–74010 Engine Balancer Backlash Adjusting Tool 09248–55020 Valve Clearance Adjust Tool Set (09248–05011) Valve Lifter Press (09248–05021) Valve Lifter Stopper 09249–63010 Torque Wrench Adaptor 09226–10010 Crankshaft Front & Rear Bearing Replacer 09278–54012 Drive Shaft Holding Tool Camshaft timing pulley 09330–00021 Companion Flange Holding Tool Crankshaft pulley 09616–30011 Steering Worm Bearing Adjusting Screw Wrench Oil pump pulley 09816–30010 Oil Pressure Switch Socket Knock sensor 09843–18020 Diagnosis Check Wire RECOMMENDED TOOLS 09090–04010 Engine Sling Device 09200–00010 Engine Adjust Kit For suspension engine EG1–6 5S–FE ENGINE 09256–00030 Hose Plug Set – ENGINE MECHANICAL Plug for vacuum hose, fuel hose etc. 09904–00010 Expander Set EQUIPMENT Battery specific gravity gauge Caliper gauge CO/HC meter Compression gauge Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune–up tester Heater Magnetic finger Micrometer Piston ring compressor Piston ring expander Plastigage Precision straight edge Soft brush Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench EG1–7 5S–FE ENGINE – ENGINE MECHANICAL Valve seat cutter Vernier calipers SSM (SERVICE SPECIAL MATERIALS) 08826–00080 Seal packing or equivalent Camshaft bearing cap Cylinder head cover Rear oil sear retainer 08833–00070 Adhesive 1311, THREE BOND 1311 or equivalent Flywheel or drive plate bolt EG1–8 5S–FE ENGINE – ENGINE MECHANICAL TUNE–UP ENGINE COOLANT INSPECTION 1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The engine coolant level should be between the “LOW” and “FULL” lines at low temperature. If low, check for leaks and add engine coolant up to the “FULL” 2. CHECK ENGINE COOLANT QUALITY There should be no excessive deposits of rust or scales around the radiator cap or radiator filler hole, and the engine coolant should be free from oil. If excessively dirty, replace the engine coolant. ENGINE OIL INSPECTION 1. CHECK OIL QUALITY Check the oil for deterioration, entry of water, dis– coloring or thinning. If oil quality is visibly poor, replace it. Oil grade: API grade SG or SH, Energy Conserving II multi– grade engine oil or ILSAC multigrade engine oil. Recommended viscosity is as shown in the illustra– tion. 2. CHECK ENGINE OIL LEVEL The oil level should be between the “L” and “F” marks on the dipstick. If low, check for leakage and add oil up to the “F” mark. EG1–9 5S–FE ENGINE – ENGINE MECHANICAL BATTERY INSPECTION 1. Except Delco Battery: CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. A. Maintenance Free Battery If under the lower level, replace the battery (or add distilled water if possible). Check the charging system. B. Except Maintenance Free Battery If under the “LOWER” or “MIN” line, add distilled water. 2. Except Delco Battery: CHECK BATTERY VOLTAGE AND SPECIFIC GRAVITY A. Maintenance Free Battery Measure the battery voltage between the terminals negative (–) and positive (+) of the battery. Standard voltage: 12.7 – 12.9 V at 20°C (68°F) HINT: • Before measuring the voltage, turn the ignition switch to LOCK and turn off the electrical sys– tems (headlight, blower motor, rear defogger etc.) for 60 seconds to remove the surface charge. • If the vehicle has been running, wait 5 minutes or more after the vehicle stops before measuring the battery voltage. If the voltage is less than specification, charge the battery. HINT: Check the indicator as shown in the illustration. EG1–10 5S–FE ENGINE – ENGINE MECHANICAL B. Except Maintenance Free Battery Check the specific gravity of each cell. Standard specific gravity: 55D23L battery for GNB Incorporated 1.25 – 1.27 at 20°C (68°F) 55D23L battery for JOHNSON CONTROLS 1.26 – 1.28 at 27°C (81°F) 80D26L battery for GNB Incorporated 1.27 – 1.29 at 20°C (68°F) 80D26L battery for JOHNSON CONTROLS 1.28 – 1.30 at 27
C (81
F) If the gravity is less than specification, charge the battery. HINT: Check the indicator as shown in the illustration. 3. Delco Battery: CHECK HYDROMETER Green Dot visible: Battery is adequately charged Dark (Green Dot not visible): Battery must be charged Clear or Light Yellow: Replace battery HINT: There is no need to add water during the entire service life of the battery. AIR FILTER INSPECTION 1. INSPECT AIR FILTER Visually check that the element is not excessively dirty, damaged or oily. 2. CLEAN AIR FILTER Clean the element with compressed air. First blow air from the inside thoroughly. Then blow off the outside of the element. HIGH–TENSION CORDS INSPECTION 1. DISCONNECT HIGH–TENSION CORDS FROM SPARK PLUGS Disconnect the high – tension cords at the rubber boot. Do not pull on the high–tension cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. EG1–11 5S–FE ENGINE – ENGINE MECHANICAL 2. CALIFORNIA ONLY: DISCONNECT HIGH–TENSION CORD FROM IGNITION COIL 3. DISCONNECT HIGH –TENSION CORDS FROM DISTRIBUTOR CAP 4. INSPECT HIGH–TENSION CORD RESISTANCE Using an ohmmeter, measure the resistance. Maximum resistance: 25 k
per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the high – tension cord. 5. RECONNECT HIGH–TENSION CORDS TO DISTRIBUTOR CAP 6. CALIFORNIA ONLY: RECONNECT HIGH–TENSION CORD TO IGNITION COIL 7. RECONNECT HIGH–TENSION CORDS TO SPARK PLUGS GENERATOR DRIVE BELT INSPECTION INSPECT DRIVE BELT (a) Visually check the drive belt for excessive wear, frayed cords etc. If any defect has been found, replace the drive belt. HINT: Cracks on the rib side of a drive belt are consid– ered acceptable. If the drive belt has chunks missing from the ribs, it should be replaced. (b) Using a belt tension gauge, measure the belt tension. Belt tension gauge: Nippondenso BTG–20 (95506–00020) Borroughs No. BT–33–73F EG1–12 5S–FE ENGINE – ENGINE MECHANICAL Drive belt tension: w/ A/C New belt 175 ± 5 lbf Used belt 130 ± 10 lbf w/o A/C New belt 125 ± 25 lbf Used belt 95 ± 20 lbf If the belt tension is not as specified, adjust it. HINT: • “New belt” refers to a belt which has been used less than 5 minutes on a running engine. • “Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. • After installing a belt, check that it fits properly in the ribbed grooves. • Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. • After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. VALVE CLEARANCE INSPECTION AND ADJUSTMENT HINT: Inspect and adjust the valve clearance when the engine is cold. 1. DISCONNECT HIGH – TENSION CORDS FROM SPARK PLUGS Disconnect the high – tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 2. REMOVE CYLINDER HEAD COVER (a) Disconnect the PCV hoses. (b) Loosen the 2 wire harness clamp bolts (No.2 timing belt cover) mounting bolts. (c) Remove the 4 nuts, grommets, head cover and gasket. EG1–13 5S–FE ENGINE – ENGINE MECHANICAL HINT: Arrange the grommets in correct order, so that they can be reinstalled into their original positions. This minimizes any possibility of oil leakage due to reuse of grommets. 3. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley and align its groove with timing mark “0” of the No.1 timing belt cover. (b) Check that the valve lifters on the No.1 cylinder are loose and valve lifters on the No.4 are tight. If not, turn the crankshaft one revolution (360*) and align the mark as above. 4. INSPECT VALVE CLEARANCE (a) Check only the valves indicated. Using a thickness gauge, measure the clearance between the valve lifter and camshaft. Record the out– of –specification valve clear– ance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake 0.19 – 0.29 mm (0.007 – 0.011 in.) Exhaust 0.28 – 0.38 mm (0.011 – 0.015 in.) (b) Turn the crankshaft one revolution (360
) and align the mark as above. (See procedure in step 3) (c) Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) EG1–14 5S–FE ENGINE – ENGINE MECHANICAL 5. ADJUST VALVE CLEARANCE (a) Remove the adjusting shim. • Turn the crankshaft so that the cam lobe for the valve to be adjusted faces up. • Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). SST 09248 – 55020 (09248 – 05011, 09248–05021) HINT: Before pressing down the valve lifter, position its notch toward the spark plug side. • Remove the adjusting shim with a’ small screw– driver and magnetic finger. HINT: For easy removed of the shim, when positioning SST (B), set it on the lifter so there is space enough to be able to remove the shim. (b) Determine the replacement adjusting shim size by following the Formula or Charts: • Using a micrometer, measure the thickness of the removed shim. • Calculate the thickness of a new shim so that the valve clearance comes within specified value. T ........... Thickness of removed shim A ........... Measured valve clearance N ........... Thickness of new shim Intake: N = T + (A – 0.24 mm (0.009 in.)) Exhaust: N = T + (A – 0.33 mm (0.013 In.)) • Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in seventeen sizes in incre– ments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.). EG1–15 5S–FE ENGINE – ENGINE MECHANICAL (c) Install a new adjusting shim. • Place a new adjusting shim on the valve lifter. • Using SST (A), press down the valve lifter and remove SST (B). SST 09248–50020 (09248–05011, 09248–05021) (d) Recheck the valve clearance. 6. REINSTALL CYLINDER HEAD COVER (a) Remove any old packing (FIPG) material. (b) Apply seal packing to the cylinder head as shown in the illustration. Seal pecking: Part No.08826–00080 or equivalent (c) Install the gasket to the head cover. (d) Install the head cover with the 4 grommets and nuts. Uniformly tighten the nuts in several passes. Torque: 23 N–m (230 kgf–cm. 17 ft–lbf) HINT: Install the grommets so that their markings are as shown in the illustration. (e) Tighten the 2 wire harness clamp (No.2 timing belt cover) mounting bolts. (f) Connect the PCV hoses. 7. RECONNECT HIGH–TENSION CORDS TO SPARK PLUGS EG1–16 5S–FE ENGINE – FE ENGINE – ENGINE MECHANICAL EG1–17 5S–FE ENGINE – ENGINE MECHANICAL EG1–18 5S–FE ENGINE – ENGINE MECHANICAL IGNITION TIMING INSPECTION AND ADJUSTMENT 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. CONNECT TACHOMETER AND TIMING LIGHT TO ENGINE Connect the test probe of a tachometer to terminal IG (–) of the data link connector 1. NOTICE: • NEVER allow the tachometer terminal to touch ground as it could result in damage to the igniter and/or ignition coif. • As some tachometers are not compatible with this Ignition system, we recommend that you confirm the compatibility of yours before use. 3. ADJUST IGNITION TIMING (a) Using SST, connect terminals TE1 and E1 of the data link connector 1. SST 09843–18020 HINT: After engine speed is kept at 1,000 – 1,300 rpm for 5 seconds, check that it returns to idle speed. (b) Using a timing light, check the ignition timing. Ignition timing: 10
BTDC @ idle (Transmission in neutral position) EG1–19 5S–FE ENGINE – ENGINE MECHANICAL (c) Loosen the bolt (California) or 2 bolts (except Califor– nia), and adjust by turning the distributor. (d) Tighten the bolt (California) or 2 bolts (except Califor– nia), and recheck the ignition timing. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) (e) Remove the SST. SST 09843–18020 4. FURTHER CHECK IGNITION TIMING Ignition timing: 0 – 10
BTDC @ idle (Transmission in neutral position) HINT: The timing mark moves in a range between 0
and 10
. 5. DISCONNECT TACHOMETER AND TIMING LIGHT FROM ENGINE EG1–20 5S–FE ENGINE – ENGINE MECHANICAL IDLE SPEED INSPECTION 1. INITIAL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) All pipes and hoses of air induction system connected (d) All vacuum lines properly connected (e) MFI/SFI system wiring connectors fully plugged (f) All operating accessories switched OFF (g) Ignition timing set correctly (h) Transmission in neutral position 2. CONNECT TACHOMETER Connect the test probe of a tachometer to terminal IG (–) of the data link connector 1. NOTICE: • Never allow the tachometer terminal to touch ground as it could result in damage to the Igniter and/or ignition coil. • As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of yours before use. 3. INSPECT IDLE SPEED (a) Race the engine at 2,500 rpm for approx. 90 seconds. (b) Check the idle speed. Idle speed (w/ Cooling fan OFF): 750±50 rpm If the idle speed is not as specified, check the IAC system. 4. DISCONNECT TACHOMETER EG1–21 5S–FE ENGINE – ENGINE MECHANICAL IDLE AND OR 2,500 RPM CO/HC CHECK HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INITIAL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) All pipes and hoses of air induction system connected (d) All accessories switched OFF (e) All vacuum lines properly connected HINT: All vacuum hoses for EGR systems, etc. should be properly connected. (f) MFI/SFI system wiring connectors fully plugged (g) Ignition timing set correctly (h) Transmission in neutral position (i) Tachometer and CO/HC meter calibrated by hand. 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATTELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM Complete the measuring within 3 minutes. HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. EG1–22 5S–FE ENGINE – ENGINE MECHANICAL Troubleshooting If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given below. (a) Check oxygen sensor operation. (See page EG1–231) (b) See the table below for possible causes, then inspect and correct the applicable causes if necessary. Problems High Normal Rough idle High Low Rough idle (Fluctuating HC reading) High High Rough idle (Black smoke from exhaust) Causes 1. Faulty ignitions: • Incorrect timing • Fouled, shorted or improperly gapped plugs • Open or crossed high–tension cords • Cracked distributor cap 2. Incorrect valve clearance 3. Leaky EGR valve 4. Leaky intake and exhaust valves 5. Leaky cylinder 1. Vacuum leaks: • PCV hose • EGR valve • Intake manifold • Throttle body • !AC valve • Brake booster line 2. Lean mixture causing misfire 1. Restricted air filter 2. Faulty MFI/SFI systems • Faulty pressure regulator • Clogged fuel return line • Defective engine coolant temp. sensor • Defective intake air temp. sensor • Faulty ECM • Faulty injector • Faulty throttle position sensor • MAP sensor EG1–23 5S–FE ENGINE – ENGINE MECHANICAL COMPRESSION CHECK HINT: If there is lack of power, excessive oil consump– tion or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. DISCONNECT DISTRIBUTOR CONNECTOR(S) 3. DISCONNECT HIGH –TENSION CORDS FROM SPARK PLUGS Disconnect the high – tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the spark plug. 5. CHECK CYLINDER COMPRESSION PRESSURE (a) Insert a compression gauge into the spark plug hole. (b) Fully open the throttle. (c) While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,226 kPa (12.5 kgf/cm
. 178 psi) or more Minimum pressure: 981 kPa (10.0 kgf/cm
, 142 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm
. 14 psi) or less EG1–24 5S–FE ENGINE – ENGINE MECHANICAL (e) If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylin– der through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. • If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damaged. • If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 6. REINSTALL SPARK PLUGS Using a 16 mm plug wrench, install the spark plug. Torque: 18 N–m (180 kgf–cm, 13 ft–lbf) 7. RECONNECT HIGH–TENSION CORDS TO SPARK PLUGS 8. RECONNECT DISTRIBUTOR CONNECTOR(S) EG1–25 5S–FE ENGINE – ENGINE MECHANICAL TIMING BELT COMPONENTS FOR REMOVAL AND INSTALLATION EG1–26 5S–FE ENGINE – ENGINE MECHANICAL TIMING BELT REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE ENGINE COOLANT RESERVOIR TANK (a) Disconnect the reservoir hose. (b) While pushing the tab of the bracket, remove the reservoir tank. 3. REMOVE GENERATOR (See page CH–10) 4. REMOVE RH FRONT WHEEL 5. REMOVE RH FENDER APRON SEAL 6. REMOVE PS DRIVE BELT Loosen the 2 bolts, and remove the drive belt. 7. SLIGHTLY JACK UP ENGINE Raise the engine enough to remove the weight from the engine mounting on the right side. 8. REMOVE ENGINE MOVING CONTROL ROD Remove the 3 bolts and control rod. 9. DISCONNECT CONNECTOR FROM GROUND WIRE ON RH FENDER APRON EG1–27 5S–FE ENGINE – ENGINE MECHANICAL 10. REMOVE No.2 ENGINE MOUNTING BRACKET Remove the 3 bolts and mounting bracket. 11. REMOVE SPARK PLUGS (a) Disconnect the high – tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. (b) Using a 16 mm plug wrench, remove the spark plug. 12. REMOVE NO.2 TIMING BELT COVER Remove the 5 bolts, timing belt cover and 2 gaskets. 13. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley and align its groove with timing mark “0” of the No.1 timing belt cover. EG1–28 5S–FE ENGINE – ENGINE MECHANICAL (b) Check that the hole of the camshaft timing pulley is aligned with the timing mark of the bearing cap. If not, turn the crankshaft one revolution (360’*). 14. REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEY HINT (When re–using timing belt): Place the match– marks on the timing belt and camshaft timing pulley, and place matchmark on timing belt to match the end of the No.1 timing belt cover. (a) Loosen the mounting bolt of the No.1 idler pulley and shift the pulley toward the left as far as it will go, and temporarily tighten it. (b) Remove the timing belt from the camshaft timing pulley. 15. REMOVE CAMSHAFT TIMING PULLEY Using SST, remove the bolt, plate washer and timing pulley. SST 09249–63010 and 09278–54012 EG1–29 5S–FE ENGINE – ENGINE MECHANICAL 16. REMOVE CRANKSHAFT PULLEY (a) Using SST, remove the pulley bolt. SST 09213–54015 (91651– 60855), 09330–00021 HINT (When re–using timing belt): After loosening the crankshaft pulley bolt, check that the timing belt matchmark aligns with the end of the No. 1 timing belt cover when the crankshaft pulley groove is aligned with the timing mark “0” of the No. 1 timing belt cover. If the matchmark does not align, align as follows: When matchmark is misaligned clockwise: • Align the matchmark by pulling the timing belt up on the water pump pulley side while turning the crankshaft pulley counterclockwise. • After aligning the matchmark, hold the timing belt, turn the crankshaft pulley clockwise, and align its groove with timing mark “0” of the No.1 timing belt cover. When matchmark is misaligned counterclockwise: • Align the rnatchmarks by pulling the timing belt up on the No.1 idler pulley side while turning the crankshaft pulley clockwise. EG1–30 5S–FE ENGINE – ENGINE MECHANICAL • After aligning the matchmark, hold the timing belt, turn the crankshaft pulley counterclockwise, and align its groove with timing mark “0” of the No.1 timing belt cover. (b) Using SST, remove the pulley. SST 09213–60017 (09213–00020, 09213–00030, 09213–00060) HINT (When re–using timing belt): Remove the pulley without turning it. 17. REMOVE No.1 TIMING BELT COVER Remove the 4 bolts, timing belt cover and gasket. 18. REMOVE TIMING BELT GUIDE 19. REMOVE TIMING BELT HINT (When re–using timing belt): Draw a direction arrow on the timing belt (in the direction of engine revolution), and place matchmarks on the timing belt and crankshaft timing pulley. EG1–31 5S–FE ENGINE – ENGINE MECHANICAL 20. REMOVE NO.1 IDLER PULLEY AND TENSION SPRING Remove the bolt, pulley and tension spring. 21. REMOVE NO.2 IDLER PULLEY Remove the bolt and pulley. 22. REMOVE CRANKSHAFT TIMING PULLEY If the pulley cannot be removed by hand, use 2 screw– drivers. HINT: Position shop rags as shown to prevent damage. 23. REMOVE OIL PUMP PULLEY Using SST, remove the nut and pulley. SST 09616–30011 TIMING BELT COMPONENTS INSPECTION 1. INSPECT TIMING BELT NOTICE: • Do not bend, twist or turn the timing belt Inside out. • Do not allow the timing belt to come into contact with oil, water or steam. EG1–32 5S–FE ENGINE • – ENGINE MECHANICAL Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley. If there are any defects as shown in the illustration, check the following points: (a) Premature parting • Check for proper installation. • Check the timing cover gasket for damage and proper installation. (b) If the belt teeth are cracked or damaged, check to see if either camshaft or water pump is locked. (c) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock. (d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. (e) If there is noticeable wear on the belt teeth, check the timing cover for damage, correct gasket installation, and for foreign material on the pulley teeth. If necessary, replace the timing belt. EG1–33 5S–FE ENGINE – ENGINE MECHANICAL 2. INSPECT IDLER PULLEYS Check that the idler pulley turns smoothly. If necessary, replace the idler pulley. 3. INSPECT TENSION SPRING (a) Measure the free length of tension spring. Free length: 46.0 mm (1.811 in.) If the free length is not as specified, replace the tension spring. (b) Measure the tension of the tension spring at the specified installed length. Installed tension (at 50.5 mm (1.988 in.)): Green color 32 – 37 N (3.25 – 3.75 k9f, 7.2 – 8.3 lbf) Silver color 47 – 52 N (4.75 – 5.25 kgf, 10.5 – 11.8 lbf) If the installed tension is not as specified, replace the tension spring. TIMING BELT INSTALLATION (See Components for Removal and Installation) 1. INSTALL OIL PUMP PULLEY (a) Align the cutouts of the pulley and shaft, and slide on the pulley. (b) Using SST, install the nut. SST 09616 – 30011 Torque: 28 N–m (290 kgf–cm, 21 ft–lbf) EG1–34 5S–FE ENGINE – ENGINE MECHANICAL 2. INSTALL CRANKSHAFT TIMING PULLEY (a) Align the timing pulley set key with the key groove of the pulley. (b) Slide on the timing pulley, facing the flange side inward. 3. INSTALL NO.2 IDLER PULLEY (a) Install the pulley with the bolt. Torque: 42 N–m (425 kgf–cm, 31 ft–lbf) HINT: Use a bolt 35 mm (1.38 in.) in length. (b) Check that the idler pulley moves smoothly. 4. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND TENSION SPRING (a) Install the pulley with the bolt. Do not tighten the bolt yet. HINT: Use a bolt 42 mm (1.65 in.) in length. (b) Install the tension spring. (c) Pry the pulley toward the left as far as it will go and tighten the bolt. (d) Check that the idler pulley moves smoothly. 5. TEMPORARILY INSTALL TIMING BELT NOTICE: The engine should be cold. (a) Using the crankshaft pulley bolt, turn the crankshaft and position the key groove of the crankshaft timing pulley upward. (b) Remove any oil or water on the crankshaft pulley, oil pump pulley, water pump pulley, No. 1 idler pulley, No. 2 idler pulley and keep them clean. (c) Install the timing belt on the crankshaft timing pulley, oil pump pulley, No.1 idler pulley, water pump pulley and No.2 idler pulley. HINT (When re–using timing belt): Align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution. EG1–35 5S–FE ENGINE – ENGINE MECHANICAL 6. INSTALL TIMING BELT GUIDE Install the guide, facing the cup side outward. 7. INSTALL NO.1 TIMING BELT COVER (a) Install the gasket to the timing belt cover. (b) Install the timing belt cover with the 4 bolts. 8. INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key with the key groove of the pulley, and slide on the pulley. (b) Using SST, install the pulley bolt. SST 09213–54015 (91651 –60855) 09330–00021 Torque: 108 N–m (1,100 kgf–cm, 80 ft–lbf) 9. INSTALL CAMSHAFT TIMING PULLEY (a) Align the camshaft knock pin with the knock pin groove of the pulley, and slide on the timing pulley. (b) Using SST, install the plate washer and bolt. SST 09249 – 63010 and 09278 – 54012 Torque: 37 N–m (380 kgf–cm, 27 ft–lbf) HINT: Use a torque wrench with a fulcrum length of 340 cm (13.39 in.) 10. SET No.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley, and align its groove with timing mark “0” of the No.1 timing belt cover. EG1–36 5S–FE ENGINE – ENGINE MECHANICAL (b) Using SST, turn the camshaft, and align the hole of the camshaft timing pulley with the timing mark of the bearing cap. SST 09278–54012 11. INSTALL TIMING BELT HINT. (When re–using timing belt): • Check that the matchmark on the timing belt matches the end of the No.1 timing belt cover. If the matchmark does not align, shift the meshing of the timing belt and crankshaft timing pulley until they align. (See page EG1–29) • Align the matchmarks of the timing belt and camshaft timing pulley. (a) Remove any oil or water on the camshaft timing pulley, and keep it clean. (b) Install the timing belt, and check the tension between the crankshaft timing pulley and camshaft timing pulley. 12. CHECK VALVE TIMING (a) Loosen the No.1 idler pulley bolt 1/2 turn. EG1–37 5S–FE ENGINE – ENGINE MECHANICAL (b) Turn the crankshaft pulley 2 revolutions from TDC to TDC. NOTICE: Always turn the crankshaft clockwise. (c) Check that each pulley aligns with the timing marks as shown in the illustration.. If the timing marks do not align, remove the timing belt and reinstall it. (d) w/ Green Tension Spring: Slowly turn the crankshaft pulley 1 and 7/8 revolu– tions, and align its groove with the mark at 45
BTDC (for No.1 cylinder) of the No.1 timing belt cover. NOTICE: Always turn the crankshaft clockwise. (e) Torque the mounting bolt of the No.1 idler pulley. Torque: 42 N–m (425 kgf–cm, 31 ft–lbf) 13. INSTALL NO.2 TIMING BELT COVER (a) Install the 2 gaskets to the No. 1 and No.2 belt covers. (b) install the belt cover with the 5 bolts. (c) Align the 2 clamps of the engine wire with cover mounting bolts. EG1–38 5S–FE ENGINE – ENGINE MECHANICAL 14. INSTALL SPARK PLUGS (a) Using a 16 mm plug wrench, install the spark plug. (b) Connect the high–tension cords. 15. INSTALL NO.2 ENGINE MOUNTING BRACKET (a) Temporarily install the No.2 engine mounting bracket with the 2 bolts. (b) Install the remaining bolt. (c) Tighten the 3 bolts in the sequence shown. Torque: 52 N–m (530 kgf–cm, 38 ft–lbf) 16. CONNECT CONNECTOR TO GROUND WIRE ON RH FENDER APRON 17. INSTALL ENGINE MOVING CONTROL ROD (a) Temporarily install the engine moving control rod with the 3 bolts in the sequence shown. EG1–39 5S–FE ENGINE – ENGINE MECHANICAL (b) Tighten the 3 bolts in the sequence shown. Torque: 64 N–m (650 kgf–cm. 47 ft–lbf) 18. INSTALL AND ADJUST PS DRIVE BELT Install the drive belt with the pivot and adjusting bolts. Drive belt tension: New belt 125 ± 25 lbf Used belt 80 ± 20 I bf 19. INSTALL RH FENDER APRON SEAL 20. INSTALL RH FRONT WHEEL 21. INSTALL GENERATOR (See page CH–24) Drive belt tension: w/ A/C New belt 175 ± 5 lbf Used belt 130 ± 10 lbf w/o A/C New belt 125 ± 25 lbf Used belt 95 ± 20 lbf 22. INSTALL ENGINE COOLANT RESERVOIR TANK 23. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG1–40 5S–FE ENGINE – ENGINE MECHANICAL CYLINDER HEAD COMPONENTS FOR REMOVAL AND INSTALLATION EG1–41 5S–FE ENGINE – ENGINE MECHANICAL COMPONENTS (Cont’d) EG1–42 5S–FE ENGINE – ENGINE MECHANICAL CYLINDER HEAD REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. DRAIN ENGINE COOLANT 3. A/T: DISCONNECT THROTTLE CABLE FROM THROTTLE BODY 4. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY 5. REMOVE AIR CLEANER CAP, RESONATOR AND AIR CLEANER HOSE (a) Disconnect the intake air temperature sensor connec– tor. (b) California only: Disconnect the air hose from the air cleaner hose. (c) Loosen the air cleaner hose clamp bolt. (d) Disconnect the 4 air cleaner cap clips. (e) Disconnect the air cleaner hose from the throttle body, and remove the air cleaner cap together with the resonator and air cleaner hose. 6. REMOVE GENERATOR (See page CH–10) 7. REMOVE DISTRIBUTOR (See page IG–13 end 32) 8. DISCONNECT FRONT EXHAUST PIPE (a) Loosen the 2 bolts, and disconnect the bracket. (b) Using a 14 mm deep socket wrench, remove the 3 nuts holding the front exhaust pipe to the WU–TWC. (c) Disconnect the front exhaust pipe and gaskets. EG1–43 5S–FE ENGINE – ENGINE MECHANICAL 9. REMOVE EXHAUST MANIFOLD AND WARM UP THREE–WAY CATALYTIC CONVERTER ASSEMBLY (a) Disconnect the main oxygen and sub oxygen sensor connectors. (b) Remove the 4 bolts and upper heat insulator. (c) Remove the bolt, nut and No. 1 manifold stay. (d) Remove the bolt, nut and manifold stay. (e) Remove the 6 nuts, the exhaust manifold and WU – TWC assembly. 10. SEPARATE EXHAUST MANIFOLD AND WARM UP THREE–WAY CATALYTIC CONVERTER Remove the following parts: (1) 3 bolts (2) Manifold lower heat insulator (3) 8 bolts (4) 2 WU–TWC heat insulators EG1–44 5S–FE ENGINE – ENGINE MECHANICAL (5) 3 bolts and 2 nuts (6) Exhaust manifold (7) Gasket (8) Retainer (9) Cushion (10) WU–TWC 11. DISCONNECT OIL PRESSURE SWITCH CONNECTOR 12. DISCONNECT ENGINE WIRE (FOR OXYGEN SENSORS) FROM ENGINE HANGER 13. REMOVE WATER OUTLET (a) Disconnect the following connectors: (1) Engine coolant temperature sender gauge con– nector (2) Engine coolant temperature sensor connector (b) Disconnect the following hoses: (1) Upper radiator hose (2) Water bypass pipe hose (3) Heater water hose (4) IAC water bypass hose (5) 2 TVV (for EVAP) vacuum hoses (c) Remove the 2 bolts, water outlet and gasket. 14. REMOVE WATER BYPASS PIPE (a) Disconnect the following hoses: (1) IAC water bypass hose (2) Heater water hose (3) w/ Oil Cooler: 2 oil cooler water bypass hoses EG1–45 5S–FE ENGINE – ENGINE MECHANICAL (b) Remove the 2 bolts, 2 nuts, water bypass pipe and gasket. (c) Remove the O–ring from the water bypass hose. 15. REMOVE THROTTLE BODY (a) Disconnect the throttle position sensor connector. (b) Disconnect the IAC valve connector. (c) Disconnect the following hoses from the throttle body. (1) PCV hose (2) 2 vacuum hoses from EGR vacuum modulator (3) Vacuum hose from TVV (for EVAP) (d) Type A: Remove the 4 bolts. (e) Type B: Remove the 2 bolts and 2 nuts. (f) Disconnect the following hoses from the throttle body, and remove the throttle body. (1) Water bypass hose from water outlet (2) Water bypass hose from water bypass pipe (3) California: Air hose from cylinder head Except California: Air hose from air tube EG1–46 5S–FE ENGINE – ENGINE MECHANICAL I6. REMOVE EGR VALVE AND VACUUM MODULATOR (a) Disconnect the EGR gas temperature sensor connec– tor. (b) Disconnect the following hoses: (1) 2 vacuum hoses from VSV (for EGR) (2) Vacuum hose from charcoal canister (c) Disconnect the vacuum hose clamp. (d) Loosen the union nut of the EGR pipe, and remove the 2 nuts, EGR valve, vacuum modulator, vacuum hoses assembly and gasket. 17. DISCONNECT VACUUM HOSES Disconnect the following hoses: (1) MAP sensor hose from air intake chamber (2) Brake booster vacuum hose from air intake cha– mber (3) PS vacuum hose from air intake chamber (4) Vacuum sensing hose from fuel pressure regula– tor 1 S. W/ A/C: DISCONNECT A/C IDLE–UP VALVE CONNECTOR 19. EXCEPT CALIFORNIA: REMOVE AIR TUBE (a) Disconnect the following hoses from the air tube: (1) w/ A/C: Air hose from ASV (2) 2 air hoses from PS pump (b) Remove the 3 bolts, wire clamp and air tube. EG1–47 5S–FE ENGINE – ENGINE MECHANICAL 20. CALIFORNIA: REMOVE AIR TUBE (a) Disconnect the following hoses: (1) w/ A/C: A/C hose (from ASV) from air tube (2) 2 air hoses (from PS pump) from air tube (3) California only: 2 vacuum hoses from VSV (for fuel pressure control) (4) Vacuum hose from air intake chamber (b) Remove the 3 bolts, wire clamp and air tube. 21. DISCONNECT 2 ENGINE WIRE GROUND STRAPS FROM INTAKE MANIFOLD 22. DISCONNECT KNOCK SENSOR AND VSV (FOR EGR) CONNECTORS 23. CALIFORNIA ONLY: DISCONNECT VSV (FOR FUEL PRESSURE CON– TROL) CONNECTOR 24. REMOVE VSV OR VSV ASSEMBLY 25. REMOVE INTAKE MANIFOLD (a) Remove the 4 bolts, wire bracket, No.1 air intake chamber and manifold stays. (b) Remove the bolt, vacuum hose bracket, and discon– nect the engine wire. (c) Remove the6 bolts, 2 nuts, intake manifold and gasket. EG1–48 5S–FE ENGINE – ENGINE MECHANICAL (d) Disconnect the 2 wire clamps from the wire brackets on the intake manifold. 26. REMOVE DELIVERY PIPE AND INJECTORS (a) Disconnect the injector connectors. (b) Loosen the pulsation damper, and disconnect the fuel inlet hose. (c) Disconnect fuel return hose. (d) Remove the 2 bolts and delivery pipe together with the 4 injectors. NOTICE: Be careful not to drop the injectors when rem– oving the delivery pips. (e) Remove the 4 insulators (except California) and 2 spacers from the cylinder head. (f) Pull out the 4 injectors from the delivery pipe. (g) California: Remove the 2 O–rings, insulator and grommet from each injector. (h) Except California: Remove the 0–ring and grommet from each injector. EG1–49 5S–FE ENGINE – ENGINE MECHANICAL 27. REMOVE CAMSHAFT TIMING PULLEY (See steps 2 to 15 on pages EG1–26 to 28) 28. REMOVE NO. 1 IDLER PULLEY AND TENSION SPRING Remove the bolt, pulley and tension spring. 29. REMOVE NO.3 TIMING BELT COVER Remove the 4 bolts and timing and cover. NOTICE: • • • Support the timing belt, :o the meshing of crank– shaft timing pulley and timing belt does not shift. Be careful not to drop anything inside the timing belt cover. Do not allow the belt to come into correct with oil, water or dust. 30. REMOVE ENGINE HANGERS Remove the bolt and engine hanger. Remove the 2 engine hangers. Remove the ground strap. 31. REMOVE GENERATOR BRACKET Remove the 3 bolts and generator bracket. 32. REMOVE OIL PRESSURE SWITCH 33. REMOVE CYLINDER HEAD COVER Remove the 4 nuts, grommets, head cover and gasket. EG1–50 5S–FE ENGINE – ENGINE MECHANICAL HINT: Arrange the grommets in correct order, so that they can be reinstalled into their original positions. This minimizes any possibility of oil leakage due to reuse of grommets. 34. REMOVE HIGH – TENSION CORDS CLAMP AND PCV VALVE 35. REMOVE CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. A. Remove exhaust camshaft (a) Set the knock pin of the intake camshaft at 10–45° BTDC of camshaft position. HINT: The above angle allows No.2 and No.4 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly. (b) Secure the exhaust camshaft sub gear to drive gear with a service bolt. Recommended service bolt: Thread diameter6 mm Thread pitch 1.0 mm Bolt length 16–20 m m (0.63–0.79 in.) HINT: When removing the camshaft, make sure that the torsional spring force of the sub gear has been eliminated by the above operation. EG1–51 5S–FE ENGINE – ENGINE MECHANICAL (c) Remove the 2 bolts and rear bearing cap. (d) Uniformly loosen and remove the6 bolts on the No. 1, No.2 and No.4 bearing caps in several passes in the sequence shown. NOTICE: Do not remove the No.3 bearing cap bolts at this stage. (e) Remove the No. 1, No.2 and No.4 bearing caps. (f) Alternately loosen and remove the 2 bolts on the No. 3 bearing cap. HINT: • As the 2 No.3 bearing cap bolts are loosened, make sure that the camshaft is lifted out straight and level. • If the camshaft is not being lifted out straight and level, retighten the 2 No.3 bearing cap bolts. Then reverse the order of above steps from (f) to (a) and reset the knock pin of the intake camshaft at 10–45
BTDC, and repeat steps from (b) to (f) once again. NOTICE: Do not pry on or attempt to force the camshaft with a tool or other object. (g) Remove the No.3 bearing cap and exhaust camshaft. B. Remove intake camshaft (a) Set the knock pin of the intake camshaft at 80–115
BTDC of camshaft angle. HINT: The above angle allows the No.1 and No.3 cylinder cam lobes of intake camshaft to push their valve lifters evenly. EG1–52 5S–FE ENGINE – ENGINE MECHANICAL (b) Remove the 2 bolts, front bearing cap and oil seal. (c) Uniformly loosen and remove the6 bolts on the No.1, No.3 and No.4 bearing caps in several passes in the sequence shown. NOTICE: Do not remove the No.2 bearing cap bolts at this stage. (d) Remove the No. 1, No.3 and No.4 bearing caps. (e) Alternately loosen and remove the 2 bolts on the No. 2 bearing cap. HINT: • As the 2 No.2 bearing cap bolts are loosened, make sure that the camshaft is lifted out straight and level, after breaking adhesion on the front bearing cap. • If the camshaft is not being lifted out straight and level, retighten the 2 No.2 bearing cap bolts. Reverse the order of above steps from (e) to (a) and reset the knock pin of the intake camshaft at 80–115*6TDC, and repeat steps from (b) to (e) once again. NOTICE: Do not pry on or attempt to force the camshaft with a tool or other object. (f) Remove the No.2 bearing cap and camshaft. 36. DISASSEMBLE EXHAUST CAMSHAFT (a) Mount the hexagon wrench head portion of the cam– shaft in a vise. NOTICE: Be careful not to damage the camshaft. EG1–53 5S–FE ENGINE – ENGINE MECHANICAL (b) Insert a service bolt (A) into the service hole of the camshaft sub gear. (c) Using a screwdriver, turn the sub gear clockwise, and remove the service bolt (B). NOTICE: Be careful not to damage the camshaft. (d) Using snap ring pliers, remove the snap ring. (e) Remove the following parts: (1) Wave washer (2) Camshaft sub gear (3) Camshaft gear spring 37. REMOVE CYLINDER HEAD (a) Using SST, uniformly loosen and remove the 10 cylin– der head bolts in several passes, in the sequence shown. SST 09011– 38121 NOTICE: Cylinder head warpage or cracking could result from removing bolts in incorrect order. EG1–54 5S–FE ENGINE – ENGINE MECHANICAL (b) Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench. HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. CYLINDER HEAD DISASSEMBLY (See Components for Removal and Installation) 1. REMOVE VALVE LIFTERS AND SHIMS HINT: Arrange the valve lifters and shims in correct order. 2. REMOVE VALVES (a) Using SST, compress the valve spring and remove the 2 keepers. SST 09202 – 70010 (b) Remove the spring retainer, valve spring, valve and spring seat. HINT: Arrange the valves, valve springs, spring seats and spring retainers in correct order. EG1–55 5S–FE ENGINE – ENGINE MECHANICAL (c) Using needle–nose pliers, remove the oil seal. CYLINDER HEAD COMPONENTS INSPECTION, CLEANING AND REPAIR 1. CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK (a) Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface. (b) Using a gasket scraper, remove all the gasket material from the cylinder block surface. (c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed air. 2. CLEAN CYLINDER HEAD A. Remove gasket material Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface. B. Clean combustion chambers Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact surface. EG1–56 5S–FE ENGINE – ENGINE MECHANICAL C. Clean valve guide bushings Using a valve guide bushing brush and solvent, clean all the guide bushings. D. Clean cylinder head Using a soft brush and solvent, thoroughly clean the cylinder head. 3. INSPECT CYLINDER HEAD A. Inspect for flatness Using a precision straight edge and thickness gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage. Maximum warpage: Cylinder block side 0.05 mm (0.0020 in.) Manifold side 0.08 mm (0.0031 in.) If warpage is greater than maximum, replace the cylin– der head. B. Inspect for cracks Using a dye penetrant, check the combustion cham– bers, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. EG1–57 5S–FE ENGINE – ENGINE MECHANICAL 4. CLEAN VALVES (a) Using a gasket scraper, chip off any carbon from the valve head. (b) Using a wire brush, thoroughly clean the valve. 5. INSPECT VALVE STEMS AND GUIDE BUSHINGS (a) Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 6.010 –6.030 mm (0.2366 – 0.2374 in.) (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake 5.970 – 5.985 mm (0.2350 – 0.2356 in.) Exhaust 5.965 – 5.980 mm (0.2348 – 0.2354 In.) (c) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025 – 0.060 mm (0.0010 – 0.0024 in.) Exhaust 0.030 – 0.065 mm (0.0012 – 0.0028 in.) Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 In.) If the clearance is greater than maximum, replace the valve and guide bushing. EG1–58 5S–FE ENGINE – ENGINE MECHANICAL 6. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS (a) w/ Snap Ring: Insert an old valve wrapped with tape into the valve guide bushing, and break off the valve guide bushing by hitting it with a hammer. Remove the snap ring. HINT: Wrap the tape approx. 8 mm (0.31 in.) from the valve stem end. NOTICE: Be careful not to damage the valve lifter hole. (b) Gradually heat the cylinder head to 80–100°C (176– 212°F). (c) Using SST and a hammer, tap out the guide bushing. SST 09201–70010 (d) Using a caliper gauge, measure the bushing bore di– ameter of the cylinder head. Both intake and exhaust Bushing bore diameter mm (in.) Bushing size 11.000 – 11.027 10.4331 – 0.4341) Use STD 11.050 – 11.077 (0.4350 – 0.4361) Use O/S 0.05 (e) Select a new guide bushing (STD size or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 11.027 mm (0.4341 in.), machine the bushing bore to the following dimension: 11.050 – 11.077 mm (0.4350 – 0.4301 in.) If the bushing bore diameter of the cylinder head is greater than 11.077 mm (0.4361 in.), replace the cylinder head. EG1–59 5S–FE ENGINE – ENGINE MECHANICAL (f) Gradually heat the cylinder head to 80 –100
C (117
– 212
F). (g) Using SST and a hammer, tap in a new guide bushing until the snap ring makes contact with the cylinder head. SST 09201– 70010 (h) Using a sharp6 mm reamer, ream the guide bushing to obtain the standard specified clearance (See page EG1–57) between the guide bushing and valve stem. 7. INSPECT AND GRIND VALVES (a) Grind the valve enough to remove pits and carbon. (b) Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5
(c) Check the valve head margin thickness. Standard margin thickness: 0.8 – 1.2 mm (0.031 – 0.047 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than minimum, replace the valve. EG1–60 5S–FE ENGINE – ENGINE MECHANICAL (d) Check the valve overall length. Standard overall length: Intake 97.60 mm (3.8425 in.) Exhaust 98.45 mm (3.8760 in.) Minimum overall length: Intake 97.1 mm (3.823 in.) Exhaust 98.0 mm (3.858 in.) If the overall length is less than minimum, replace the valve. (e) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. NOTICE: Do not grind off more than minimum. 8. INSPECT AND CLEAN VALVE SEATS (a) Using a 45
carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats. (b) Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve. (c) Check the valve face and seat for the following: If blue appears 360
around the face, the valve is concentric. If not, replace the valve. EG1–61 5S–FE ENGINE – ENGINE MECHANICAL • If blue appears 360
around the valve seat, the guide and face are concentric. If not, resurface the seat. • Check that the seat contact is in the middle of the valve face with the following width: 1.0 – 1.4 mm (0.039 – 0.055 in.) If not, correct the valve seat as follows: (1) If the seating is too high on the valve face, use 30
and 45
cutters to correct the seat. (2) If the seating is too low on the valve face, use 75
and 45
cutters to correct the seat. (d) Hand–lap the valve and valve seat with an abrasive compound. (e) After hand–lapping, clean the valve and valve seat. 9. INSPECT VALVE SPRINGS (a) Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than maximum, replace the valve spring. (b) Using a vernier caliper, measure the free length of the valve spring. Free length: 41.96 – 41.99 mm (1.6520 – 1.6531 in.) If the free length is not as specified, replace the valve spring. EG1–62 5S–FE ENGINE – ENGINE MECHANICAL (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 164 – 189 N (16.7 – 19.3 kgf, 36.8 – 42.5 lbf) at 34.7 mm (1.336 in.) If the installed tension is not as specified, replace the valve spring. 10. INSPECT CAMSHAFTS AND BEARINGS A. Inspect camshaft for runout (a) Place the camshaft on V – blocks. (b) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.04 mm (0.0016 in.) If the circle runout is greater than maximum, replace the camshaft. B. Inspect cam lobes Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake 42.01 – 42.11 mm (1.6539 – 1.6579 in.) Exhaust 40.06 – 40.18 mm (1.5772 – 1.5811 In.) Minimum cam lobe height: Intake 41.90 mm (1.6496 in.) Exhaust 39.95 mm (1.5728 in.) If the cam lobe height is less than minimum, replace the camshaft. C. Inspect camshaft journals Using a micrometer, measure the journal diameter. Journal diameter: 26.959 – 28.975 mm 11.0814 – 1.0620 in.) If the journal diameter is not as specified, check the oil clearance. EG1–63 5S–FE ENGINE – ENGINE MECHANICAL D. Inspect camshaft bearings Check that bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set. E. Inspect camshaft gear spring Using a vernier caliper, measure the free distance between the spring ends. Free distance: 22.5 – 22.9 mm (0.886 – 0.902 in.) If the free distance is not as specified, replace the gear spring. F. Inspect camshaft journal oil clearance (a) Clean the bearing caps and camshaft journals. (b) Place the camshafts on the cylinder head. (c) Lay a strip of Plastigage across each of the camshaft journals. (d) Install the bearing caps. (See step 4 on pages EG1–69 to 71) Torque: 19 N–m (190 kgf–cm, 14 ft–lbf) NOTICE: Do not turn the camshaft. (e) Remove the bearing caps. EG1–64 5S–FE ENGINE – ENGINE MECHANICAL (f) Measure the Plastigage at its widest point. Standard oil clearance: 0.025 – 0.062 mm (0.0010 – 0.0024 In.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (g) Completely remove the Plastigage. G. Inspect camshaft thrust clearance (a) Install the camshaft. (See step 4 on pages EG1–69 to 71) (b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: Intake 0.045 – 0.100 mm (0.0018 – 0.0039 in.) Exhaust 0.030 – 0.085 mm (0.0012 – 0.0033 in.) Maximum thrust clearance: Intake 0.12 mm (0.0047 in.) Exhaust 0.10 mm (0.0039 in.) If the thrust clearance is greater than maximum, re– place the camshaft. If necessary, replace the bearing caps and cylinder head as a set. H. Inspect camshaft gear backlash (a) Install the camshafts without installing the exhaust cam sub gear. (See step 4 on pages EG1–69 to 71) (b) Using a dial indicator, measure the backlash. Standard backlash: 0.020 – 0.200 mm (0.0008 – 0.0079 in.) Maximum backlash: 6.30 mm (0.0188 in.) If the backlash is greater then maximum, replace the camshafts. EG1–65 5S–FE ENGINE – ENGINE MECHANICAL 11. INSPECT VALVE LIFTERS AND LIFTER BORES (a) Using a caliper gauge, measure the lifter bore diame– ter of the cylinder head. Lifter bore diameter: 31.000 – 31.018 mm (1.2205 – 1.2213 In.) (b) Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 – 30.976 mm (1.2191 – 1.2195 in.) (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024 – 0.052 mm (0.0009 – 0.0020 in.) Maximum oil clearance: 0.07 mm (0.0028 In.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head. 12. INSPECT MANIFOLDS Using a precision straight edge and feeler gauge, mea– sure the surface contacting the cylinder head for war– page. Maximum warpage: 0.30 mm (0.0 118 In.) If warpage is greater than maximum, replace the man– ifold. EG1–66 5S–FE ENGINE – ENGINE MECHANICAL CYLINDER HEAD ASSEMBLY (See Components for Removal and Installation) HINT: • Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and rotating surfaces. • Replace all gaskets and oil seals with new ones. 1. INSTALL VALVES (a) Using SST, push in a new oil seal. SST 09201 –41020 HINT: The intake valve oil seal is brown and the exhaust valve oil seal is black. (b) Install the following parts: (1) Valve (2) Spring seat (3) Valve spring (4) Spring retainer (c) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202 – 70010 EG1–67 5S–FE ENGINE – ENGINE MECHANICAL (d) Using a plastic–faced hammer, lightly tap the valve stem tip to assure proper fit. 2. INSTALL VALVE LIFTERS AND SHIMS (a) Install the valve lifter and shim. (b) Check that the valve lifter rotates smoothly by hand. CYLINDER HEAD INSTALLATION (See Components for Removal and Installation) 1. INSTALL CYLINDER HEAD A. Place cylinder head on cylinder block (a) Place a new cylinder head gasket in position on the cylinder block. NOTICE: Be careful of the installation direction. (b) Place the cylinder head in position on the cylinder head gasket. B. Install cylinder head bolts HINT: • The cylinder head bolts are tightened in 2 progressive steps (steps (b) and (d)). • If any cylinder head bolt is broken or deformed, re– place it. (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (b) Using SST, install and uniformly tighten the 10 cylin– der head bolts and plate washers in several passes, in the sequence shown. SST 09011– 38121 Torque: 49 N–m (500 kgf–cm, 36 ft–lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. EG1–68 5S–FE ENGINE – ENGINE MECHANICAL (c) Mark the front of the cylinder head bolt head with paint. (d) Retighten the cylinder head bolts 90
in the sequence shown on the previous page. (e) Check that the painted mark is now at a 90
angle to front. 2. INSTALL SPARK PLUG TUBES (a) Clean the cylinder head tube holes of any residua! adhesive, oil or foreign particles. Remove any oil with kerosene or gasoline. (b) Screw the threads of the spark plug tube coated with adhesive into the cylinder head. (c) Using the spark plug tube nut and a 30 mm socket wrench, tighten the spark plug tubes. Torque: 39 N–m (400 kgf–cm, 29 ft–lbf) 3. ASSEMBLY EXHAUST CAMSHAFT (a) Mount the hexagon wrench head portion of the cam– shaft in a vise. NOTICE: Be careful not to damage the camshaft. (b) Install the following parts: (1) Camshaft gear spring (2) Camshaft sub gear (3) Wave washer HINT: Align the pins on the gears with the spring ends. EG1–69 5S–FE ENGINE – ENGINE MECHANICAL (c) Using snap ring pliers, install the snap ring. (d) Insert a service bolt (A) into the service hole of the camshaft sub gear. (e) Using a screwdriver, align the holes of the camshaft main gear and sub gear by turning camshaft sub gear clockwise, and install a service bolt (13). NOTICE: Be careful not to damage the camshaft. 4. INSTALL CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. A. Install intake camshaft (a) Apply MP grease to the thrust portion of the cam– shaft. (b) Place the intake camshaft at 80–115° BTDC of cam– shaft angle, on the cylinder head. HINT: The above angle arrows the No.1 and No.3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly. (c) Apply seal packing to the No. 1 bearing cap as shown. Seal packing: Part No.08826 –00080 or equivalent EG1–70 5S–FE ENGINE – ENGINE MECHANICAL (d) Install the bearing caps in their proper locations. (e) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. (f) Install and uniformly tighten the 10 bearing cap bolts in several passes, in the sequence shown. Torque: 19 N–m (190 kgf–cm, 14 ft–lbf) (g) Apply MP grease to a new oil seal lip. (h) Using SST, tap in the oil seal. SST 09223–4601 1 B. Install exhaust camshaft (a) Set the knock pin of the intake camshaft at 10–45° BTDC of camshaft angle. HINT: The above angle allows the No.2 and No.4 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly. EG1–71 5S–FE ENGINE – ENGINE MECHANICAL (b) Apply MP grease to the thrust portion of the cam– shaft. (c) Engage the exhaust camshaft gear to the intake cam– shaft gear by matching the timing marks on each gear. (d) Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other. NOTICE: There are also assembly reference marks on each gear as shown in the Illustration. Do not use these marks. (e) Turn the intake camshaft clockwise or counterclockwise little by little until the exhaust camshaft sits in the bearing journals evenly without rocking the cam– shaft on the bearing journals. NOTICE: It is very important to replace the camshaft in the bearing journals evenly while tightening bearing caps in the subsequent steps. (f) Install the bearing caps in their proper locations. (g) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. (h) Install and uniformly tighten the 10 bearing cap bolts in several passes, in the sequence shown. Torque: 19 N–m (190 kgf–cm, 14 ft–lbf) (i) Remove the service bolt (B). 5. CHECK AND ADJUST VALVE CLEARANCE (See page EG1–12) Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance. Valve clearance (Cold): Intake 0.19 – 0.29 mm (0.007 – 0.011 In.) Exhaust 0.28 – 0.38 mm (0.011 – 0.015 In.) EG1–72 5S–FE ENGINE – ENGINE MECHANICAL 6. INSTALL SEMI–CIRCULAR PLUGS (a) Remove any old packing (FIPG) material. (b) Apply seal packing to the semi–circular plug grooves. Seal packing: Part No.08826–00080 or equivalent (c) Install the 2 semi–circular plugs to the cylinder head. 7. INSTALL PCV VALVE AND HIGH–TENSION CORDS CLAMP 8. INSTALL CYLINDER HEAD COVER (a) Remove any old packing (FIPG) material. (b) Apply seal packing to the cylinder head as shown in the illustration. Seal packing: Part No.08826–00080 or equivalent EG1–73 5S–FE ENGINE – ENGINE MECHANICAL (c) Install the gasket to the head cover. (d) Install the head cover with the 4 grommets and nuts. Uniformly tighten the nuts in several passes. Torque: 23 N–m (230 kgf–cm, 17 ft–lbf) HINT: Install the grommets so that their markings are as shown in the illustration. 9. INSTALL OIL PRESSURE SWITCH Apply adhesive to 2 or 3 threads. Adhesive: Part No.08833–00080, THREE BOND 1324 or equivalent 10. INSTALL GENERATOR BRACKET Install the generator bracket with the 3 bolts. Torque: 42 N–m (425 kgf–cm, 31 ft–lbf) 11. INSTALL ENGINE HANGERS Install the engine hanger with the bolt. Install the 2 engine hangers. Install the ground strap. Torque: 25 N–m (250 kgf–cm, 18 ft–lbf) 12. INSTALL NO.3 TIMING BELT COVER Install the timing belt cover with the 4 bolts. Torque: 7.8 N–m (80 kgf–cm, 69 in–lbf) EG1–74 5S–FE ENGINE – ENGINE MECHANICAL 13. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND TENSION SPRING (a) Install the pulley with the bolt. Do not tighten the bolt yet. HINT: Use bolt 42 mm (1.65 in.) in length. (b) Install the tension spring. (c) Pry the pulley toward the left as far as it will go and tighten the bolt. (d) Check that the idler pulley moves smoothly. 14. INSTALL CAMSHAFT TIMING PULLEY AND TIMING BELT (See page EG1–33) 15. INSTALL INJECTORS AND DELIVERY PIPE (a) California: Install new insulator and grommet to each injector. (b) Except California: Install a new grommet to each injector. (c) California: Apply a light coat of gasoline to 2 new 0–rings, and install them to each injector. (d) Except California: Apply a light coat of gasoline to a new 0–ring, and install it to each injector. (e) While turning the injector left and right, install it to the delivery pipes. Install the 4 injectors. EG1–75 5S–FE ENGINE – ENGINE MECHANICAL (f) Install the following parts to the intake manifold: (1) 2 spacers (2) Except California: 4 new insulators (g) Place the 4 injectors together with the delivery pipe in position on the cylinder head. (h) Temporarily install the 2 bolts holding the delivery pipe to the cylinder head. (i) Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O–rings. Replace the O–rings. (j) Position the injector connector upward. (k) Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) (l) Connect the fuel return hose. (m) Connect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the pulsation damper. Torque: 34 N–m (350 kgf–cm, 25 ft–lbf) EG1–76 5S–FE ENGINE – ENGINE MECHANICAL 16. INSTALL INTAKE MANIFOLD (a) Connect the 2 wire clamps to the wire brackets on the intake manifold. (b) Install a new gasket and the intake manifold with the 6 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) (c) Install the vacuum hose bracket and engine wire har– ness with the bolt. (d) Install the No.1 air intake chamber and manifold stays, wire bracket with the 4 bolts. 14 mm head bolt Torque: 42 N–m (425 kgf–cm, 31 ft–lbf) 12 mm head bolt Torque: 22 N–m (220 kgf–cm, 16 ft–lbf) 17. INSTALL VSV OR VSV ASSEMBLY 18. CALIFORNIA ONLY: CONNECT VSV (FOR FUEL PRESSURE CONTROL) CONNECTOR 19. CONNECT KNOCK SENSOR AND VSV (FOR EGR) CONNECTORS 20. INSTALL 2 ENGINE WIRE GROUND STRAPS TO INTAKE MANIFOLD 21. CALIFORNIA: INSTALL AIR TUBE (a) Install the air tube and wire clamp with the 3 bolts. EG1–77 5S–FE ENGINE – ENGINE MECHANICAL (b) Connect the following hoses: (1) w/ A/C: A/C hose (from ASV) to air tube (2) 2 air hoses (from PS pump) to air tube (3) 2 vacuum hoses to VSV (for fuel pressure con– trol) (4) Vacuum hose to air intake chamber 22. EXCEPT CALIFORNIA: INSTALL AIR TUBE (a) Install the air tube and wire clamp with the 3 bolts. (b) Connect the following hoses to the air tube: (1) w/ A/C: Air hose from ASV (2) 2 air hose from PS pump 23. CONNECT VACUUM HOSES Connect the following hoses: (1) MAP sensor hose to air intake chamber (2) Brake booster vacuum hose to air intake chamber (3) PS vacuum hose to air intake chamber (4) Vacuum sensing hose to fuel pressure regulator. 24. w/ A/C: CONNECT A/C IDLE–UP VALVE CONNECTOR 25. INSTALL EGR VALVE AND VACUUM MODULATOR (a) Install a new gasket and the EGR valve with the union nut and 2 nuts. Union nut: Torque: 59 N–m (600 kgf–cm, 43 ft–lbf) Nut: Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) (b) Install the EGR modulator to the clamp. EG1–78 5S–FE ENGINE – ENGINE MECHANICAL (c) Connect the vacuum hose clamp. (d) Connect the following hoses: (1) Vacuum hose to charcoal canister (2) Vacuum hose (from EGR valve) to E port of VSV (for EGR) (3) Vacuum hose (from Q port of EGR vacuum mod– ulator) to G port of VSV (for EGR) (e) Connect the EGR gas temperature sensor connector. 26. INSTALL THROTTLE BODY (a) Connect the following hoses to the throttle body: (1) Water bypass hose from water outlet (2) Water bypass hose from water bypass pipe (3) California: Air hose from cylinder head Except California: Air hose from air tube (b) Place a new gasket on the intake chamber, facing the protrusion downward. (c) Type A: Install the throttle body with the 4 bolts. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) HINT: Each bolt is indicated in the illustration. Bolt length: A 45 mm (1.77 in.) B 55 mm (2.17 in.) (d) Type e: Install the throttle body with the 2 bolts and 2 nuts. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) (e) Connect the following hoses to the throttle body: (1) PCV hose (2) 2 vacuum hoses from EGR vacuum modulator (3) Vacuum hose from TVV (for EVAP) EG1–79 5S–FE ENGINE – ENGINE MECHANICAL (f) Connect the IAC valve connector. (g) Connect the throttle position sensor connector. 27. INSTALL WATER BYPASS PIPE (a) Install a new 0–ring to the bypass pipe. (b) Apply soapy water on the 0– ring. (c) Install a new gasket and the bypass pipe with the 2 nuts and 2 bolts. Torque (Nut): 8.8 N–m (90 kgf–cm. 78 in.–lbf) (d) Connect the following hoses: (1) IAC water bypass hose (2) Heater water hose (3) w/ Oil Cooler: 2 oil cooler water bypass hoses 28. INSTALL WATER OUTLET (a) Install a new gasket and the water outlet with the 2 bolts. Torque: 15 N–m (150 kgf–cm, 11 ft–lbf) (b) Connect the following hoses: (1) Upper radiator hose (2) Water bypass pipe hose (3) Heater water hose (4) IAC water bypass hose (5) TVV (for EVAP) vacuum hose (from P port of throttle body) (6) TVV (for EVAP) vacuum hose (from charcoal canister) EG1–80 5S–FE ENGINE – ENGINE MECHANICAL (c) Connect the following connectors: (1) Engine coolant temperature sender gauge con– nector (2) Engine coolant temperature sensor connector 29. CONNECT ENGINE WIRE (FOR OXYGEN SENSORS) TO ENGINE HANGER 30. CONNECT OIL PRESSURE SWITCH CONNECTOR 31. ASSEMBLE EXHAUST MANIFOLD AND WARM UP THREE–WAY CATALYTIC CONVERTER Assemble the following parts: (1) WU–TWC (2) Cushion (3) Retainer (4) Gasket (5) Exhaust manifold (6) 3 bolts and 2 nuts Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) (7) 2 converter heat insulators (8) 8 bolts (9) Manifold lower heat insulator (10) 3 bolts 32. INSTALL EXHAUST MANIFOLD AND WARM UP THREE–WAY CATALYTIC CONVERTER ASSEMBLY (a) Install a new gasket, the exhaust manifold and WU – TWC assembly with the 6 nuts. Uniformly tighten the nuts in several passes. Torque: 49 N–m (540 kgf–cm, 36 ft–lbf) EG1–81 5S–FE ENGINE – ENGINE MECHANICAL (b) Install the manifold stay with the bolt and nut. Torque: 42 N–m (425 kgf–cm, 31 ft–lbf) (c) Install the No. 1 manifold stay with the bolt and nut. Torque: 42 N–m (425 kgf–cm, 31 ft–lbf) (d) Install the manifold upper heat insulator with the 4 bolts. (e) Connect the main oxygen and sub oxygen sensor connectors. 33. CONNECT FRONT EXHAUST PIPE (a) Place a new gasket on the front exhaust pipe. (b) Using a 14 mm deep socket wrench, install the 3 new nuts holding the front exhaust pipe to the WU –TWC. Torque: 62 N–m (630 kgf–cm, 46 ft–lbf) (c) Install the bracket with the 2 bolts. 34. INSTALL DISTRIBUTOR (See page IG–17 and 37) 35. INSTALL GENERATOR (See page CH–24) 36. INSTALL AIR CLEANER CAP, RESONATOR AND AIR CLEANER HOSE (a) Connect the air cleaner hose to the throttle body. (b) Install the air cleaner cap together with the resonator and air cleaner hose. (c) California only: Connect the air hose to the air cleaner hose. (d) Connect the intake air temperature sensor connector. EG1–82 5S–FE ENGINE – ENGINE MECHANICAL 37. A/T: CONNECT AND ADJUST THROTTLE CABLE 38. CONNECT AND ADJUST ACCELERATOR CABLE 39. FILL WITH ENGINE COOLANT Capacity: 6.3 liters (6.7 US qts, 5.5 Imp. qts) 40. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 41. START ENGINE AND CHECK FOR LEAKS 42. ADJUST IGNITION TIMING (See page IG –19 and 38) Ignition timing: 10
BTDC @ idle (w/ Terminals TO and E1 connected) 43. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 44. RECHECK ENGINE COOLANT LEVEL AND OIL LEVEL EG1–83 5S–FE ENGINE – ENGINE MECHANICAL CYLINDER BLOCK COMPONENTS FOR ENGINE REMOVAL AND INSTALLATION EG1–84 5S–FE ENGINE – ENGINE MECHANICAL EG1–85 5S–FE ENGINE – ENGINE MECHANICAL ENGINE REMOVAL 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable Is discon– nected from the battery. 2. REMOVE BATTERY AND TRAY 3. REMOVE HOOD 4. REMOVE ENGINE UNDER COVER 5. DRAIN ENGINE COOLANT 6. DRAIN ENGINE OIL 7. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY 8. A/T: DISCONNECT THROTTLE CABLE FROM THROTTLE BODY 9. REMOVE AIR CLEANER ASSEMBLY, RESONATOR AND AIR CLEANER HOSE (a) Disconnect the intake air temperature sensor connec– tor. (b) California only: Disconnect the air hose from the air cleaner hose. (c) Loosen the air cleaner hose clamp bolt. (d) Disconnect the 4 air cleaner cap clips. (e) Disconnect the air cleaner hose from the throttle body, and remove the air cleaner cap together with the resonator and air cleaner hose. (f) Remove the element. (g) Remove the 3 bolts and air cleaner case. 10. w/ CRUISE CONTROL SYSTEM: REMOVE CRUISE CONTROL ACTUATOR (a) Remove the actuator cover. (b) Disconnect the actuator connector. (c) Remove the 3 bolts, and disconnect the actuator with the bracket. 11. REMOVE RADIATOR EG1–86 5S–FE ENGINE – ENGINE MECHANICAL 12. DISCONNECT WIRES AND CONNECTORS (a) Remove the engine relay box, and disconnect the 5 connectors. (b) Connector from LH fender apron (c) Disconnect the following connectors: (1) Igniter connector (2) California only: Ignition coil connector (3) Noise filter connector (4) 2 ground straps from LH fender apron (5) Connector from LH fender apron (6) Data link connector 1 (7) 2 ground straps from RH fender apron (d) Disconnect the MAP sensor connector. 13. DISCONNECT HEATER HOSES 14. DISCONNECT FUEL RETURN HOSE CAUTION: Catch leaking fuel in a container. EG1–87 5S–FE ENGINE – ENGINE MECHANICAL 15. DISCONNECT FUEL INLET HOSE CAUTION: Catch leaking fuel in a container. 16. M/T: REMOVE STARTER 17. M/T: REMOVE CLUTCH RELEASE CYLINDER WITHOUT DISCONNECTING TUBE Remove the 4 bolts, release cylinder and tube from the transaxle. 18. DISCONNECT TRANSAXLE CONTROL CABLE (S) FROM TRANSAXLE 19. DISCONNECT VACUUM HOSES (a) MAP sensor hose from air intake chamber (b) Brake booster vacuum hose from air intake chamber EG1–88 5S–FE ENGINE – ENGINE MECHANICAL (c) Charcoal canister vacuum hose 20. DISCONNECT ENGINE WIRE FROM CABIN (a) Remove the under cover. (b) Remove the lower instrument panel. (c) Remove the glove compartment door. (d) Remove the glove compartment. (e) Disconnect the following connectors: (1) 2 ECM connectors (2) 2 cowl wire connector (f) Remove the 2 nuts, and pull out the engine wire from the cowl panel. EG1–89 5S–FE ENGINE – ENGINE MECHANICAL 21. w/ A/C: REMOVE A/C COMPRESSOR WITHOUT DISCONNECTING HOSES (a) Disconnect the A/C compressor connector. (b) Remove the drive belt. (c) Remove the 3 bolts, and disconnect the A/C compres– sor. HINT: Put aside the compressor, and suspend it to the radiator support with a string. 22. DISCONNECT FRONT EXHAUST PIPE (a) Loosen the 2 bolts, and disconnect the bracket. (b) Using a 14 mm deep socket wrench, remove the 3 nuts holding the front exhaust pipe to the WU–TWC. (c) Disconnect the front exhaust pipe and gaskets. 23. REMOVE DRIVE SHAFTS (See page SA–38) 24. REMOVE PS PUMP WITHOUT DISCONNECTING HOSES (a) Disconnect the 2 air hoses from the air pipe. (b) Remove the PS drive belt. (c) Remove the 2 bolts, and disconnect the PS pump from the engine. HINT: Put aside the pump and suspend it from the cowl with a string. 25. DISCONNECT LH ENGINE MOUNTING INSULATOR M/T: Remove the 3 bolts, and disconnect the mounting insulator. A/T: Remove the 4 bolts, and disconnect the mounting insulator. EG1–90 5S–FE ENGINE – ENGINE MECHANICAL 26. DISCONNECT RR ENGINE MOUNTING INSULATOR (a) Remove the hole plugs. (b) Remove the 3 nuts, and disconnect the mounting insulator. 27. DISCONNECT FR ENGINE MOUNTING INSULATOR Remove the 3 bolts, and disconnect the mounting insulator. 28. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS 29. REMOVE ENGINE MOVING CONTROL ROD Remove the 3 bolts and control rod. 30. REMOVE ENGINE AND TRANSAXLE ASSEMBLY FROM VEHICLE (a) Lift the engine out of the vehicle slowly and carefully. NOTICE: Be careful not to hit the PS gear housing or perk/neutral position switch (A/T). (b) Make sure the engine is clear of all wiring, hoses and cables. (c) Place the engine and transaxle assembly onto the stand. EG1–91 5S–FE ENGINE – ENGINE MECHANICAL 31. A/T: REMOVE STARTER 32. SEPARATE ENGINE AND TRANSAXLE M/T (See page MX–10) A/T (See page AX1–21) 33. REMOVE N0.2 RH ENGINE MOUNTING BRACKET Remove the 3 bolts and engine mounting bracket. 34. REMOVE FR ENGINE MOUNTING INSULATOR (a) Remove the bolt, nut and manifold stay. (b) Remove the 4 bolts and mounting insulator. 35. REMOVE RR ENGINE MOUNTING INSULATOR Remove the 4 bolts and mounting insulator. EG1–92 5S–FE ENGINE – ENGINE MECHANICAL COMPONENTS FOR CYLINDER BLOCK DISASSEMBLY AND ASSEMBLY EG1–93 5S–FE ENGINE – ENGINE MECHANICAL PREPARATION FOR DISASSEMBLY 1. M/T: REMOVE CLUTCH COVER AND DISC 2. M/T: REMOVE FLYWHEEL 3. A/T: REMOVE DRIVE PLATE 4. REMOVE REAR END PLATE Remove the bolt and end plate. 5. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 6. REMOVE GENERATOR 7. REMOVE DISTRIBUTOR 8. REMOVE PS PUMP BRACKET Remove the 3 bolts and PS pump bracket. 9. REMOVE TIMING BELT AND PULLEYS 10. REMOVE CYLINDER HEAD 11. REMOVE WATER PUMP AND GENERATOR ADJUSTING BAR 12. REMOVE OIL PAN AND OIL PUMP 13. REMOVE OIL FILTER 14. w/ OIL COOLER: REMOVE OIL COOLER 15. REMOVE KNOCK SENSOR Using SST, remove the knock sensor. SST 09816 – 30010 EG1–94 5S–FE ENGINE – ENGINE MECHANICAL CYLINDER BLOCK DISASSEMBLY (See Components for Cylinder Block Disassembly and Assembly) 1. REMOVE REAR OIL SEAL RETAINER Remove the 6 bolts, retainer and gasket. 2. CHECK THRUST CLEARANCES OF NO.1 AND NO.2 BALANCE SHAFT OF ENGINE BALANCER Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth. Standard thrust clearance: 0.065 – 0.110 mm (0.0026 – 0.0043 in.) Maximum clearance: 0.11 mm (0.0043 in.) If the clearance is greater than maximum, replace the balance shaft housings and bearings. If necessary, replace the balance shafts. 3. CHECK BACKLASH OF CRANKSHAFT GEAR AND NO.1 BALANCE SHAFT GEAR NOTICE: • Backlash between the crankshaft gear and No.1 balance shaft gear varies with the rotation of the balance shaft and the deviation of the crankshaft gear. • Accordingly, it is necessary to measure the backlash at the 4 points shown in the illustration on the left. When this inspection is performed on–vehicle, the specifications are increased by approx. 0.025 mm (See specifications below) (a) Rotate the crankshaft 2 or 3 times to settle the crank– shaft gear and No.1 balance shaft gear. (b) When No.1 piston is at TDC, check that the punch marks shown in the illustration of the balance shafts are aligned with the grooves of the No.2 housing. EG1–95 5S–FE ENGINE – ENGINE MECHANICAL (c) Check that the punch marks A and B are at the positions on the No.1 balance shaft indicated in the illustration. (d) 1 st turn the crankshaft clockwise, and align the groove of the No.2 balance shaft housing with the punch mark A of the No. 1 balance shaft. (e) Set the SST and the dial indicator as shown in the illustration. SST 09224– 74010 HINT: Make sure that the–needle of the dial indicator is perpendicular to the SST and that it is placed in the middle of the third indention. (f) Lightly turn the No. 1 balance shaft by hand and meas– ure the backlash. HINT: • Turn the No.1 balance shaft 4 or 5 times to provide a steady backlash reading. • To prevent excessive backlash due to thrust cle– arance, measure the backlash while pressing on the rear of the No.1 balance shaft. Standard backlash: Off–vehicle 0–0.06 mm (0–0.0024 In.) On–vehicle 0.025 – 0.080 mm (0.0010 – 0.0035 in.) NOTICE: Do not turn the No.1 balance shaft strongly. (g) Remove the dial gauge and the SST. EG1–96 5S–FE ENGINE – ENGINE MECHANICAL (h) Turn the crankshaft clockwise to align the groove of the No.2 housing with the punch mark B. (i) Set the dial gauge. (See procedure in step (e)) (j) Measure the backlash. (See procedure in step (f)) Standard backlash: 0 – 0.06 mm (0 – 0.0024 in.) (k) Remove the dial gauge. (I) Turn the crankshaft clockwise again to align the groove of the No.2 housing with the punch mark A. (m) Set the dial gauge. (See procedure in step (e)) (n) Measure the backlash. (See procedure in step (f)) Standard backlash: 0 – 0.06 mm (0 – 0.0024 in.) (o) Remove the dial gauge. (p) Turn the crankshaft clockwise again to align the groove of the No.2 housing with the punch mark B. (q) Set the dial gauge. (See procedure in step (e)) (r) Measure the backlash. (See procedure in step (f)) Standard backlash: 0 – 0.06 mm (0 – 0.0024 In.) (s) Remove the dial gauge. If even one of the 4 points measured above exceeds the backlash specification, adjust the backlash with new spacers. NOTICE: Use the same size spacers for both the left and right sides. HINT: • Varying the spacer thickness by 0.02 mm (0.0008 in.) change the backlash by about 0.014 mm (0.0006 in.). • If the backlash is greater than permitted maxi– mum, select a thinner shim. • If the backlash is less than the specification, select a thicker shim. EG1–97 5S–FE ENGINE – ENGINE MECHANICAL EG1–98 5S–FE ENGINE – ENGINE MECHANICAL 4. REMOVE ENGINE BALANCER (a) Uniformly loosen and remove the 6 bolts in several passes, in the sequence shown. (b) Remove the engine balancer and spacers. 5. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.160 – 0.312 mm (0.0063 – 0.0123 in.) Maximum thrust clearance: 0.36 mm (0.0138 in.) If the thrust clearance is greater than maximum, re– place the connecting rod assembly. If necessary, re– place the crankshaft. 6. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE (a) Check the matchmarks on the connecting rod and cap to ensure correct reassembly. (b) Using SST, remove the connecting rod cap nuts. SST 09011–38121 (c) Using a plastic–faced hammer, lightly tap the con– necting rod bolts and lift off the connecting rod cap. HINT: Keep the lower bearing inserted with the con– necting rod cap. EG1–99 5S–FE ENGINE – ENGINE MECHANICAL (d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. (e) Clean the crank pin and bearing. (f) Check the crank pin and bearing for pitting and scrat– ches. If the crank pin or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft. (g) Lay a strip of Plastigage across the crank pin. (h) Install the connecting rod cap. (See step 6 on pages EG1–122) 1st Torque: 25 N–m (250 kgf–cm, 18 ft–lbf) 2nd Turn 90° NOTICE: Do not turn the crankshaft. (i) Remove the connecting rod cap. (See procedure (b) and (c) on the previous page) EG1–100 5S–FE ENGINE – ENGINE MECHANICAL (j) Measure the Plastigage at its widest point. Standard oil clearance: STD 0.024 – 0.055 mm (0.0009 – 0.0022 in.) U/S 0.25 0.023 – 0.069 mm (0.0009 – 0.0027 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crank– shaft. HINT: If using a standard bearing, replace it with one having the same number marked on the connecting rod cap. There are 3 sizes of standard bearings, marked *11’, “2” and “3” accordingly. Standard sized bearing center wall thickness: Mark “1” 1.484 – 1.488 mm (0.0584 – 0.0586 in.) Mark “2” 1.488 – 1.492 mm (0.0586 – 0.0587 in.) Mark “3” 1.492 – 1.498 mm (0.0587 – 0.0589 in.) (k) Completely remove the Plastigage. 7. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES (a) Using a ridge reamer, remove all the carbon from the top of the cylinder. (b) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. (c) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. EG1–101 5S–FE ENGINE – ENGINE MECHANICAL HINT: • Keep the bearings, connecting rod and cap to– gether. • Arrange the piston and connecting rod assembl– ies in correct order. 8. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.020 – 0.220 mm (0.0008 – 0.0087 in.) Maximum thrust clearance: 0.30 mm l0.0118 in.) If the thrust clearance is greater than maximum, re– place the thrust washers as a set. Thrust washer thickness: 2.440 – 2.490 mm 10.0961 – 0.0980 in.) 9. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE (a) Uniformly loosen and remove the main bearing cap bolts in several passes, in the sequence shown. (b) Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and lower thrust wash– ers (No.3 main bearing cap only). HINT: • Keep the lower bearing and main bearing cap together. • Arrange the main bearing caps and lower thrust washers in correct order. EG1–102 5S–FE ENGINE – ENGINE MECHANICAL (c) Lift out the crankshaft. HINT: Keep the upper bearing and upper thrust wash– ers together with the cylinder block. (d) Clean each main journal and bearing. (e) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bear– ings. If necessary, grind or replace the crankshaft. (f) Place the crankshaft on the cylinder block. (g) Lay a strip of Plastigage across each journal. (h) Install the main bearing caps. (See step 4 on page EG1–121) Torque: 59 N–m (600 kgf–cm, 43 ft–lbf) NOTICE: Do not turn the crankshaft. (i) Remove the main bearing caps. (See procedure (a) and (b) on the previous page) EG1–103 5S–FE ENGINE – ENGINE MECHANICAL Measure the Plastigage at its widest point. Standard clearance: No.3 STD 0.025 – 0.044 mm (0.0010 – 0.0017 in.) U/S 0.25 0.027 – 0.067 mm (0.0011 – 0.0026 in.) Others STD 0.015 – 0.034 mm (0.00015 – 0.0013 in.) U/S 0.25 0.019 – 0.059 mm (0.0007 – 0.0023 in.) Maximum clearance: 0.08 mm (0.0031 In.) HINT: If replacing the cylinder block subassembly, the bearing standard clearance will be: No.3: 0.027 – 0.054 mm (0.0011 – 0.0021 in.) Others 0.017 – 0.044 mm (0.0007 – 0.0017 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crank– shaft. HINT: If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylin– der block and crankshaft, then selecting the bearing with the same number as the total. There are 5 sizes of standard bearings, marked “1”, “2”, “3”, “4” and “5” accordingly. Number marked Cylinder block Crankshaft Use bearing EXAMPLE: Cylinder block “2” + Crankshaft “11” = Total number 3 (Use bearing “3”) EG1–104 5S–FE ENGINE – ENGINE MECHANICAL Reference: Cylinder block main journal bore diameter: Mark “1” 59.020 – 59.026 mm (2.32318 – 2.3239 in.) Mark “2” 59.026 – 59.032 mm (2.3239 – 2.3241 in.) Mark “3” 59.032 – 59.038 mm (2.3241 – 2.3243 in.) Crankshaft journal diameter: Mark “0” 54.998 – 55.003 mm (2.1653 – 2.1655 in.) Mark “11” 54.993–54.998 mm (2.1651 – 2.1653 in.) Mark “2” 54.988 – 54.993 mm (2.1649 – 2.1651 in.) Standard sized bearing center wall thickness: No–3 Mark “I” 1.992 – 1.995 mm (0.0784 – 0.0785 in.) Mark ’2” 1.995 – 1.998 mm (0.0785 – 0.0787 in.) Mark “3” 1.998 – 2.001 mm (0.0787 – 0.0788 in.) Mark ’4” 2.001 – 2.004 mm (0.0788 – 0.0789 in.) Mark ’5’ 2.004 – 2.007 mm (0.0789 – 0.0790 in.) Others Mark “I” 1.997 – 2.000 mm (0.0786 – 0.0787 in.) Mark ’2’ 2.000 – 2.003 mm (0.0787 – 0.0789 in.) Mark “3” 2.003 – 2.006 mm (0.0789 – 0.0790 in.) Mark ’4’ 2.006 – 2.009 mm (0.0790 – 0.0791 in.) Mark ’5’ 2.009 – 2.012 mm (0.0791 – 0.0792 in.) (k) Completely remove the Plastigage. 10. REMOVE CRANKSHAFT (a) Lift out the crankshaft. (b) Remove the upper bearings and upper thrust washers from the cylinder block. EG1–105 5S–FE ENGINE – ENGINE MECHANICAL HINT: Arrange the main bearing caps, bearings and thrust washers in correct order. CYLINDER BLOCK INSPECTION 1. CLEAN CYLINDER BLOCK A. Remove gasket material Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. B. Clean cylinder block Using a soft brush and solvent, thoroughly clean the cylinder block. 2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and thickness gauge, measure the surfaces contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 In.) If warpage is greater than maximum, replace the cylin– der block. 3. INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 4 cylin– ders. If necessary, replace the cylinder block. EG1–106 5S–FE ENGINE – ENGINE MECHANICAL 4. INSPECT CYLINDER BORE DIAMETER HINT: There are 3 sizes of the standard cylinder bore diameter, marked “1”, “2” and “3” accordingly. The mark is stamped on the top of the cylinder block. Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: STD Mark “1” 87.000 – 87.010 mm (3.4252 – 3.4256 in.) Mark “2” 87.010 – 87.020 mm (3.4256 – 3.4260 in.) Mark “3” 87.020 – 87.030 mm (3.4260 – 3.4264 In.) Maximum diameter: STD 87.23 mm (3.4342 in.) O/S 0.50 87.73 mm (3.4350 In.) If the diameter is greater than maximum, rebore all the 4 cylinders. If necessary, replace the cylinder block. 5. REMOVE CYLINDER RIDGE If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder. EG1–107 5S–FE ENGINE – ENGINE MECHANICAL PISTON AND CONNECTING ROD ASSY DISASSEMBLY 1. CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. 2. REMOVE PISTON RINGS (a) Using a piston ring expander, remove the 2 compres– sion rings. (b) Remove the 2 side rails and oil ring by hand. HINT: Arrange the rings in correct order only. 3. DISCONNECT CONNECTING ROD FROM PISTON (a) Using a small screwdriver, pry out the 2 snap rings. (b) Gradually heat the piston to 80–90
C (176–194
F). EG1–108 5S–FE ENGINE – ENGINE MECHANICAL (c) Using plastic–faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. HINT: The piston and pin are a matched set. Arrange the pistons, pins, rings, connecting rods and bearings in correct order. PISTON AND CONNECTING ROD INSPECTION 1. CLEAN PISTON (a) Using a gasket scraper, remove the carbon from the piston top. (b) Using a groove cleaning tool or broken ring, clean the piston ring grooves. (c) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush. EG1–109 5S–FE ENGINE – ENGINE MECHANICAL 2. INSPECT PISTON A. Inspect piston oil clearance HINT: There are 3 sizes of the standard piston diame– ter, marked “1”, “2” and “3” accordingly. The mark is stamped on the piston top. (a) Using a micrometer, measure the piston diameter at ring angles to the piston pin center line, 23.5 mm (0.925 in.) from the piston head. Piston diameter: STD Mark “I” 86.85–86.86 mm (3.4193 – 3.4197 in.) Mark “2” 86.86–86.87 mm (3.4197 – 3.4201 In.) Mark “3” 86.87 – 86.88 mm (3.4201 – 3.4205 in.) O/S 0.50 87.35 – 87.38 mm (3.4390 – 3.4402 in.) (b) Measure the cylinder bore diameter in the thrust di– rections. (See step 4 on page EG1–106) (c) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.14 – 0.16 mm (0.0055 – 0.0063 in.) Maximum oil clearance: 0.18 mm (0.0071 in.) If the oil clearance is greater than maximum, replace all the 4 pistons and rebore all the 4 cylinders. If necessary, replace the cylinder block. HINT (Use new cylinder block): Use a piston with the same number mark as the cylinder bore diameter marked on the cylinder block. EG1–110 5S–FE ENGINE – ENGINE MECHANICAL B. Inspect piston ring groove clearance Using a thickness gauge, measure the clearance be– tween new piston ring and the wall of the piston ring groove. Ring groove clearance: No.1 0.040 – 0.080 mm (0.0016 – 0.0031 In.) No.2 0.030 – 0.070 mm (0.0012 – 0.0028 in.) If the clearance is greater than maximum, replace the piston. C. Inspect piston ring end gap (a) Insert the piston ring into the cylinder bore. (b) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 115 mm (4.53 in.) from the top of the cylinder block. (c) Using a thickness gauge, measure the end gap. Standard and gap: No.1 0.270 – 0.500 mm (0.0106 – 0.0197 in.) No.2 0.350 – 0.600 mm (0.0138 – 0.0234 in.) Oil (Side rail) 0.200 – 0.550 mm (0.0079 – 0.0217 in.) Maximum end gap: No.1 1.10 mm (0.0433 in.) No.2 1.20 mm (0.0472 In.) Oil (Side rail) 1.15 mm (0.0453 In.) If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, rebore all the 4 cylinders or replace the cylinder block. EG1–111 5S–FE ENGINE – ENGINE MECHANICAL D. Inspect–piston pin fit At 60
C (140
F), you should be able to push the piston pin into the piston pin hole with your thumb. 3. INSPECT CONNECTING ROD A. Inspect connecting rod alignment Using a rod aligner and thickness gauge, check the connecting rod alignment. • Check for bend. Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.94 In.) If bend is greater than maximum, replace the connect– ing rod assembly. • Check for twist Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connect– ing rod assembly. B. Inspect piston pin oil clearance (a) Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 – 22.017 mm (0.8663 – 0.8668 in.) (b) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 – 22.009 mm (0.8660 – 0.8865 in.) EG1–112 5S–FE ENGINE – ENGINE MECHANICAL (c) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 – 0.011 mm (0.0002 – 0.0004 in.) Maximum oil clearance: 0.05 mm (0.0020 In.) If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set. C. If necessary, replace connecting rod bushing (a) Using SST and a press, press out the bushing. SST 09222 – 30010 (b) Align the oil holes of a new bushing and the connect– ing rod. (c) Using SST and a press, press in the bushing. SST 09222–30010 (d) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (see step B above) between the bushing and piston pin. (e) Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb. EG1–113 5S–FE ENGINE – ENGINE MECHANICAL D. Inspect connecting rod bolts (a) Install the cap nut to the connecting rod bolt. Check that the cap nut can be turned easily by hand to the end of the thread. (b) If the cap nut cannot be turned easily, measure the outside diameter of the connecting rod bolt with a vernier caliper. Standard outside diameter: 7.860–8.000 mm (0.3094–0.3150 in.) Minimum outside diameter: 7.60 mm (0.2992 in.) HINT: If the location of this area cannot be judged by visual inspection, measure the outer diameter at the location shown in the illustration. If the outside diameter is less than minimum, replace the connecting rod bolt and nut as a set. EG1–114 5S–FE ENGINE – ENGINE MECHANICAL CYLINDER BORING HINT: • Bore all the 4 cylinders for the oversized piston outside diameter. • Replace all the piston rings with ones to match the oversized pistons. 1. KEEP OVERSIZED PISTONS Oversized piston diameter: O/S 0.50 87.35 – 87.38 mm (3.4390–3.4402 in.) 2. CALCULATE AMOUNT TO BORE CYLINDERS (a) Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 23.5 mm (0.925 in.) from the piston head. (b) Calculate the amount of each cylinder is to be rebored as follows: Size to be rebored = P + C–H P = Piston diameter C = Piston clearance 0.14 – 0.18 mm (0.0055 – 0.0063 in.) H = Allowance for honing 0.20 mm (0.0008 in.) or less 3. BORE AND HONE CYLINDER TO CALCULATED DIMENSIONS Maximum honing: 0.02 mm (0.0008 in.) NOTICE: Excess honing will destroy the finished round– ness. EG1–115 5S–FE ENGINE – ENGINE MECHANICAL CRANKSHAFT INSPECTION AND REPAIR 1. INSPECT CRANKSHAFT FOR RUNOUT (a) Place the crankshaft on V–blocks. (b) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 In.) If the circle runout is greater than maximum, replace the crankshaft. 2. INSPECT MAIN JOURNALS AND CRANK PINS (a) Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: STD size 54.988 – 55.003 mm (2.1653–2.1655 in.) U/S 0.25 54.745 – 54.755 mm (2.1553–2.1557 in.) Crank pin diameter: STD size 51.985 – 52.000 mm (2.0466–2.0472 in.) U/S 0.25 51.745 – 51.755 mm (2.0372–2.0376 in.) If the diameter is not as specified, check the oil clear– ance (See pages EG1–98 to 104). If necessary, grind or replace the crankshaft. (b) Check each main journal and crank pin for taper and out–of–round as shown. Maximum taper and out–of–round: 0.02 mm (0.0008 in.) If the taper and out–of–round is greater than maxi– mum, replace the crankshaft. 3. IF NECESSARY. GRIND AND HONE MAIN JOUR– NALS AND/OR CRANK PINS Grind and hone the main journals and/or crank pins to the finished undersized diameter (See procedure in step 2). Install new main journal and/or crankshaft pin under– sized bearings. EG1–116 5S–FE ENGINE – ENGINE MECHANICAL CRANKSHAFT OIL SEALS REPLACEMENT HINT: There are 2 methods (A and B) to replace the oil seal which are as follows: 1. REPLACE CRANKSHAFT FRONT OIL SEAL A. If oil pump is removed from cylinder block: (a) Using a screwdriver and a hammer, tap out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump case edge. SST 09223 – 63010 (c) Apply MP grease to the oil seal lip. B. If oil pump is installed to the cylinder block: (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. (c) Apply MP grease to a new oil seal lip. (d) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump case edge. SST 09226 –10010 EG1–117 5S–FE ENGINE – ENGINE MECHANICAL 2. REPLACE CRANKSHAFT REAR OIL SEAL A. If rear oil seal retainer is removed from cylinder block: (a) Using screwdriver and hammer, tap out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal edge. SST 09223–63010 (c) Apply MP grease to the oil seal lip. B. If rear oil seal retainer Is installed to cylinder block: (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. (c) Apply MP grease to a new oil seal lip. (d) Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223 – 63010 EG1–118 5S–FE ENGINE – ENGINE MECHANICAL PISTON AND CONNECTING ROD ASSEMBLY 1. ASSEMBLE PISTON AND CONNECTING ROD (a) Install a new snap ring on one side of the piston pin hole. (b) Gradually heat the piston to 80–90
C (176–194
F). (c) Coat the piston pin with engine oil. (d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. (e) Install a new snap ring on the other side of the piston pin hole. 2. INSTALL PISTON RINGS (a) Install the oil ring expander and 2 side rails by hand. EG1–119 5S–FE ENGINE – ENGINE MECHANICAL (b) Using a piston ring expander, install the 2 compres– sion rings with the code mark facing upward. Code mark: N o.1 1N orT No.2 2N or 2T (c) Position the piston rings so that the ring ends are as shown. NOTICE: Do not align the ring ends. 3. INSTALL BEARINGS (a) Align the bearing claw with the groove of the connect– ing rod or connecting cap. (b) Install the bearings in the connecting rod and con– necting rod cap. CYLINDER BLOCK ASSEMBLY (See Components for Cylinder Block Disassembly and Assembly) HINT: • Thoroughly clean all parts to be assembled. • Before installing the parts, apply new engine oil to all sliding and rotating surfaces. • Replace all gaskets, 0–rings and oil seals with new parts. 1. INSTALL MAIN BEARINGS HINT: • Main bearings come in widths of 19.2 mm (0.756 in.) and 22.9 mm (0.902 in.). Install the 22.9 mm (0.902 in.) bearings in the No.3 cylinder block journal position with the main bearing cap. Install the 19.2 mm (0.756 in.) bearings in the other positions. EG1–120 5S–FE ENGINE – ENGINE MECHANICAL • Upper bearings have an oil groove and oil holes; lower bearings do not. (a) Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings. (b) Align the bearing claw with the claw groove of the main bearing cap, and push in the 5 lower bearings. HINT: A number is marked on each main bearing cap to indicate the installation position. 2. INSTALL UPPER THRUST WASHERS Install the 2 thrust washers under the No.3 journal position of the cylinder block with the oil grooves facing outward. 3. PLACE CRANKSHAFT ON CYLINDER BLOCK EG1–121 5S–FE ENGINE – ENGINE MECHANICAL 4. INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS (a) Install the 2 thrust washers on the No.3 bearing cap with the grooves facing outward. (b) Install the 5 main bearing caps in their proper loca– tions. HINT: Each bearing cap has a number and front mark. (c) Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts. (d) Install and uniformly tighten the 10 bolts of the main bearing caps in several passes, in the sequence shown. Torque: 59 N–m (600 kgf–cm, 43 ft–lbf) (e) Check that the crankshaft turns smoothly. (f) Check the crankshaft thrust clearance. Using a dial indicator, measure the thrust clear– ance while prying the crankshaft back an forth with a screwdriver. Standard thrust clearance: 0.020 – 0.220 mm (0.0008 – 0.0087 in.) Maximum thrust clearance: 0.30 mm (0.0118 In.) If the thrust clearance is greater than maximum, re– place the thrust washers as a set. 5. INSTALL PISTON AND CONNECTING ROD ASSEMBLES (a) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. EG1–122 5S–FE ENGINE – ENGINE MECHANICAL (b) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. 6. INSTALL CONNECTING ROD CAPS A. Place connecting rod cap on connecting rod (a) Match the numbered connecting rod cap with the connecting rod. (b) Install the connecting rod cap with the front mark facing forward. B. Install connecting rod cap nuts HINT: The cap nuts are tightened in 2 progressive steps (steps (b) and (d)). If any one of the connecting rod bolts is broken or deformed, replace it. (a) Apply a light of engine oil on the threads and under the nuts of the connecting rod cap. (b) Using SST, install and alternately tighten the cap nuts in several passes. SST 09011– 38121 Torque: 25 N–m (250 kgf–cm, 18 ft–lbf) If any one of the cap nuts does not meet the torque specification, replace the connecting rod bolt and cap nut as a set. (c) Mark the front of the cap nut with the paint. EG1–123 5S–FE ENGINE – ENGINE MECHANICAL (d) Retighten the cap nuts 90
as shown. (e) Check that the painted mark is now at a 90
angle to the front. (f) Check that the crankshaft turns smoothly. (g) Check the connecting rod thrust clearance. Using a dial indicator, measure the thrust clear– ance while moving the connecting rod back an forth. Standard thrust clearance: 0.160 – 0.312 mm (0.0063 – 0.0123 In.) Maximum thrust clearance: 0.35 mm 10.0138 In.) If the thrust clearance is greater than maximum, re– place the connecting rod assembly. If necessary, re– place the crankshaft. 7. INSTALL ENGINE BALANCER (a) Turn the crankshaft, and set the No. 1 cylinder TDC as shown in the illustration. (b) Set the balance shafts so that the punch marks of the balance shafts are aligned with the grooves of the No. 2 housing. EG1–124 5S–FE ENGINE – ENGINE MECHANICAL (c) Wipe clean the installation surface of the spacer. (d) Place the spacers on the cylinder block. HINT: When replacing the crankshaft and/or balance shaft, use the thickest spacers. (e) Place the engine balancer on the cylinder block. (f) Check that punch marks shown in the illustration of the balance shafts are align with the grooves of the No.2 housing. (g) While pulling the center part of the engine balancer in the direction of the arrow, uniformly tighten the 6 bolts in several passes, in the sequence shown. Torque: 49 N–m (500 kgf–cm, 36 ft–lbf) (h) Recheck that the punch marks of the balance shafts are aligned with the grooves of No.2 housing. 8. CHECK AND ADJUST BACKLASH OF CRANKSHAFT GEAR AND NO.1 BALANCE SHAFT GEAR (See page EG1–94) 9. INSTALL REAR OIL SEAL RETAINER Install a new gasket and the retainer with the 6 bolts. Torque: 9.3 N–m (95 kgf–cm, 82 in.–lbf) EG1–125 5S–FE ENGINE – ENGINE MECHANICAL POST ASSEMBLY 1. INSTALL KNOCK SENSOR Using SST, install the knock sensor. SST 09816–30010 Torque: 37 N–m (380 kgf–cm. 27 ft–lbf) 2. w/ OIL COOLER: INSTALL OIL COOLER 3. INSTALL OIL FILTER 4. INSTALL OIL PUMP AND OIL PAN 5. INSTALL WATER PUMP AND GENERATOR ADJUSTING BAR 6. INSTALL CYLINDER HEAD 7. INSTALL PULLEYS AND TIMING BELT 8. INSTALL PS PUMP BRACKET Install the PS pump bracket with 3 bolts. Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) 9. INSTALL GENERATOR 10. INSTALL DISTRIBUTOR 11. REMOVE ENGINE STAND 12. INSTALL REAR END PLATE Torque: 9.3 N–m (95 kgf–cm, 82 in.–lbf) EG1–126 5S–FE ENGINE – ENGINE MECHANICAL 13. M/T: INSTALL FLYWHEEL (a) Apply adhesive to 2 or 3 threads of the mounting bolt end. Adhesive: Part No.08833–00070. THREE BOND 1324 or equi– valent (b) Install the flywheel on the crankshaft. (c) install and uniformly tighten the mounting bolts in several passes, in the sequence shown. Torque: 88 N–m (900 kgf–cm, 66 ft–lbf) 14. A/T: INSTALL DRIVE PLATE (See procedure step 13) Torque: 83 N–m (850 kgf–cm, 61 ft–lbf) 15. M/T: INSTALL CLUTCH DISC AND COVER EG1–127 5S–FE ENGINE – ENGINE MECHANICAL ENGINE INSTALLATION (See Components for Engine Removal and Installation) 1. INSTALL RR ENGINE MOUNTING INSULATOR Install the mounting insulator with the 4 bolts. Torque: 64 N–m (650 kgf–cm. 47 ft–lbf) 2. INSTALL FR ENGINE MOUNTING INSULATOR (a) Install the mounting insulator with the 4 bolts. Torque: 77 N–m (790 kgf–cm. 57 ft–lbf) (b) Install the manifold stay with the bolt and nut. Torque: 42 N–m (425 kgf–cm, 31 ft–lbf) 3. INSTALL N0.2 ENGINE MOUNTING BRACKET (a) Temporarily install the No.2 engine mounting bracket with the 2 bolts. (b) Install the remain bolt. (c) Tighten the 3 bolts in the sequence shown. Torque: 52 N–m (530 kgf–cm, 38 ft–lbf) 4. ASSEMBLE ENGINE AND TRANSAXLE M/T (See page MX–15) A/T (See page AX1–27) 5. A/T: INSTALL STARTER EG1–128 5S–FE ENGINE – ENGINE MECHANICAL 6. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE (a) Attach the engine sling device to the engine hangers. (b) Lower the engine into the engine compartment. Tilt the transaxle downward, lower the engine and clear the LH mounting. NOTICE: Be careful not to hit the PS gear housing or park/neutral position switch (A/T). (c) Keep the engine level, and align RH and LH mountings with the body bracket. 7. INSTALL ENGINE MOVING CONTROL ROD (a) Temporarily install the engine moving control rod with the 3 bolts in the sequence shown. (b) Tighten the 3 bolts in the sequence shown. Torque: 64 N–m (650 kgf–cm, 47 ft–lbf) 8. CONNECT FR ENGINE MOUNTING INSULATOR Connect the mounting insulator with the 3 bolts. Torque: 80 N–m (820 kgf–cm. 59 ft–lbf) EG1–129 5S–FE ENGINE – ENGINE MECHANICAL 9. CONNECT RR ENGINE MOUNTING INSULATOR (a) Connect the mounting insulator with the 3 nuts. Torque: 66 N–m (670 kgf–cm, 48 ft–lbf) (b) Install the hole plugs: 10. CONNECT LH ENGINE MOUNTING INSULATOR M/T: Connect the mounting insulator with the 3 bolts. Torque: 64 N–m (650 kgf–cm, 47 ft–lbf) A/T: Connect the mounting insulator with the 4 bolts. Torque: 64 N–m (650 kgf–cm, 47 ft–lbf) 11. REMOVE ENGINE SLING DEVICE 12. INSTALL PS PUMP (a) Install the PS pump with the 2 bolts. Torque: 43 N–m (440 kgf–cm. 31 ft–lbf) (b) Install the drive belt. (c) Connect the 2 air hoses to the air pipe. 13. INSTALL DRIVE SHAFTS (See page SA–40) EG1–130 5S–FE ENGINE – ENGINE MECHANICAL 14. CONNECT FRONT EXHAUST PIPE (a) Place a new gasket on the front exhaust pipe. (b) Using a 14 mm deep socket wrench, install the 3 new nuts holding the front exhaust pipe to the WU–TWC. Torque: 82 N–m (630 kgf–cm, 46 ft–lbf) (c) Install the bracket with the 2 bolts. 15. w/ A/C: INSTALL A/C COMPRESSOR (a) Install the compressor with the 3 bolts. Torque: 27 N–m (280 kgf–cm, 20 ft–lbf) (b) Install the drive belt. (c) Connect the A/C compressor connector. 16. CONNECT ENGINE WIRE TO CABIN (a) Push in the engine wire through the cowl panel. Install the 2 nuts. (b) Connect the following connectors: (1) 2 ECM connectors (2) 2 cowl wire connectors (c) Install the glove compartment. (d) Install the glove compartment door. (e) Install the lower instrument panel. (f) Install the under cover. EG1–131 5S–FE ENGINE – ENGINE MECHANICAL 17. CONNECT VACUUM HOSES (a) MAP sensor hose to air intake chamber (b) Brake booster vacuum hose to air intake chamber (c) Charcoal canister vacuum hose 18. CONNECT TRANSAXLE CONTROL CABLE (S) TO TRANSAXLE 19. M/T: INSTALL CLUTCH RELEASE CYLINDER Install the release cylinder and tube with the 4 bolts. 20. M/T: INSTALL STARTER EG1–132 5S–FE ENGINE – ENGINE MECHANICAL 21. CONNECT FUEL INLET HOSE Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) 22. CONNECT FUEL RETURN HOSE 23. CONNECT HEATER HOSES 24. CONNECT WIRES AND CONNECTORS (a) Connect the 5 connectors to the relay box. (b) Connectors from LH fender apron. (c) Install the engine relay box. (d) Connect the following connectors: (1) Igniter connector (2) California only: Ignition coil connector (3) Noise filter connector (4) 2 ground straps from LH fender apron (5) Connector from LH fender apron EG1–133 5S–FE ENGINE – ENGINE MECHANICAL (6) Data link connector 1 (7) 2 ground straps from RH fender apron (e) Connect the MAP sensor connector. 25. INSTALL RADIATOR 26. w/ CRUISE CONTROL SYSTEM: INSTALL CRUISE CONTROL ACTUATOR (a) Install the actuator and bracket with the 3 bolts. (b) Connect the actuator connector. (c) Install the actuator cover. 27. INSTALL AIR CLEANER ASSEMBLY, RESONATOR AND AIR CLEANER HOSE (a) Install the air cleaner case with 3 bolts. (b) Install the element. (c) Connect the air cleaner hose to the throttle body. (d) Install the air cleaner cap together with the resonator and air cleaner hose. (e) California only: Connect the air hose to the air cleaner hose. (f) Connect the intake air temperature sensor connector. 28. A/T: CONNECT AND ADJUST THROTTLE CABLE 29. CONNECT AND ADJUST ACCELERATOR CABLE 30. FILL WITH ENGINE COOLANT 31. FILL WITH ENGINE OIL 32. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 33. START ENGINE AND CHECK FOR LEAKS 34. PREFORM ENGINE ADJUSTMENT 35. INSTALL ENGINE UNDER COVERS 36. INSTALL HOOD 37. PERFORM ROAD TEST Check for abnormal noises, shock, slippage, correct shift points and smooth operation. 38. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS EG1–134 5S–FE ENGINE – ENGINE MECHANICAL BALANCE SHAFT BACKLASH ADJUSTMENT ON VEHICLE 1. CHECK BACKLASH OF CRANKSHAFT GEAR AND NO.1 BALANCE SHAFT GEAR NOTICE: Backlash between the crankshaft gear and No.1 balance shaft gear varies with the rotation of the balance shaft and the deviation of the crankshaft gear. Accordingly, it is necessary to measure the backlash at the 4 points shown in the illustration on the left. (a) Rotate the crankshaft 2 or 3 times to settle the crank– shaft gear and No. 1 balance shaft gear. (b) When No.1 piston is at TDC, check that the punch marks C shown in the illustration of the balance shafts are aligned with the grooves of the No. 2 housing. (c) Check that the punch marks A and B are at the positions on the No.1 balance shaft indicated in the illustration. (d) First turn the crankshaft clockwise, and align the groove of the No.2 balance shaft housing with the punch mark A of the No. 1 balance shaft. EG1–135 5S–FE ENGINE – ENGINE MECHANICAL (e) Position the SST and dial indicator as shown in the illustration. SST 09224 – 74010 HINT: Make sure that the stem of the dial indicator is perpendicular to the SST and that it is placed in the middle of the 3rd indentation. (f) Gently turn the No.1 balance shaft by hand, until resistance is felt, and measure the backlash. HINT: • Rotate the No. 1 balance shaft 4 or 5 times to provide a steady backlash reading. • To prevent excessive backlash due to thrust cle– arance, measure the backlash while pressing on the rear of the No.1 balance shaft. Standard backlash (use SST): 0.060 – 0.100 mm (0.0024 – 0.0039 In.) NOTICE: Do not turn the No.1 balance shaft strongly. (g) Remove the dial gauge and the SST. (h) Turn the crankshaft clockwise to align the groove of the No.2 housing with the punch mark B. (i) Set the dial gauge. (See procedure in step (e)) (j) Measure the backlash. (See procedure in step (f)) Standard backlash ( use SST ): 0.080 – 0.100 mm (0.0024 – 0.0039 in.) (k) Remove the dial gauge. EG1–136 5S–FE ENGINE – ENGINE MECHANICAL (I) Turn the crankshaft clockwise again to align the groove of the No.2 housing with the punch mark A. (m) Set the dial gauge. (See procedure in step (e)) (n) Measure the backlash. (See procedure in step (f)) Standard backlash ( use SST ): 0.060 – 0.100 mm (0.0024 – 0.0039 in.) (o) Remove the dial gauge. (p) Turn the crankshaft clockwise again to align the groove of the No.2 housing with the punch mark B. (q) Set the dial gauge. (See procedure in step (e)) (r) Measure the backlash. (See procedure in step (f)) Standard backlash( use SST ): 0.06 – 0.100 mm (0.0024 – 0.0039 in.) (s) Remove the dial gauge. If even one of the 4 points measured above exceeds the backlash specification, adjust the backlash with new spacers. NOTICE: Use the same size spacers for both the left and right sides. HINT: • Varying the spacer thickness by 0.02 mm (0.0008 in.) changes the backlash by about 0.042 mrn (0.0017 in.). • If the backlash is greater than permitted maxi– mum, select a thinner shim. • If the backlash is less than the specification, select a thicker shim. EG1–137 5S–FE ENGINE – ENGINE MECHANICAL EG1–138 5S–FE ENGINE – ENGINE MECHANICAL 2. REPLACE THE SPACERS (a) Uniformly loosen the6 bolts in the sequence shown. (b) Replace the spacers with new ones. 3. TORQUE BALANCESHAFT ASSEMBLY While pulling the center part of the engine balancer in the direction of the arrow, uniformly tighten the6 bolts in several passes, in the sequence shown. Torque: 49 N–m (500 kgf–cm, 36 ft–lbf) 4. CHECK AND ADJUST BACKLASH OF CRANK– SHAFT GEAR AND No.1 BALANCE SHAFT GEAR (See procedure in step 1) EG1–139 5S–FE ENGINE – ENGINE MECHANICAL EXHAUST SYSTEM COMPONENTS EG1–140 5S–FE ENGINE SERVICE SPECIFICATIONS SERVICE DATA Idle speed Intake manifold vacuum at idle speed Compression pressure et 250 rpm Difference of pressure between each cylinder Idler pulley tension spring Free length Installed load at 50.5 mm (1.988 in.) Cylinder head Warpage Cylinder block side Manifold side Valve seat Refacing angle Contacting angle Contacting width Valve guide bushing Inside diameter Outside diameter (for repair part) Valve Valve overall length Vale face angle Stem diameter Stem oil clearance Margin thickness Valve spring Deviation Free length Installed tension et 34.7 mm (1.366 in.) Valve lifter Lifter diameter Lifter bore diameter Oil clearance Manifold Warpage – ENGINE MECHANICAL EG1–141 5S–FE ENGINE Camshaft Thrust clearance Journal oil clearance Journal diameter Circle runout Cam lobe height Camshaft gear backlash Camshaft gear spring end free distance Cylinder block Cylinder head surface warpage Cylinder bore diameter Piston and piston ring Piston diameter Piston oil clearance Piston ring groove clearance Piston ring end gap – ENGINE MECHANICAL EG1–142 5S–FE ENGINE Connecting rod Thrust clearance Connecting rod bearing center wall thickness (Reference) Connecting rod oil clearance Rod bend Rod twist Bushing inside diameter Piston pin diameter Piston pin oil clearance Connecting rod bolt outside diameter Crankshaft Thrust clearance Thrust washer thickness Main journal oil clearance Main journal diameter Main bearing center wall thickness (Reference) Crank pin diameter Circle runout Main journal taper and out–of–round Crank pin taper and out–of–round – ENGINE MECHANICAL EG1–143 5S–FE ENGINE Engine balancer Thrust clearance Backlash Crankshaft x No. 1 balance shaft Off–vehicle On–vehicle No. 1 balance shaft x No.2 balance shaft at D mark at E mark at F mark Spacer thickness Balance shaft housing bolt outer diameter TORQUE SPECIFICATIONS Part tightened Cylinder head cover x Cylinder head Spark plug x Cylinder head Oil pump pulley x Oil pump drive ’shaft No. 2 idler pulley x Cylinder block Crankshaft pulley x Crankshaft Camshaft timing pulley x Camshaft Camshaft timing pulley x Camshaft (For use with SST) No. 1 idler pulley x Cylinder heed No. 2 engine mounting bracket x Cylinder block Engine moving control rod X Fender apron Engine moving control rod x No. 2 engine mounting bracket Cylinder head x Cylinder block (1 sty – ENGINE MECHANICAL EG1–144 5S–FE ENGINE Cylinder head x Cylinder block (2nd) Spark plug tube x Cylinder head Camshaft bearing cap x Cylinder head Generator bracket x Cylinder head Engine hanger x Cylinder head No. 3 timing belt cover x Cylinder head Delivery pipe x Cylinder head Pulsation damper x Delivery pipe Intake manifold x Cylinder heed Intake manifold stay x Intake manifold Intake manifold stay x Cylinder block No. 1 air intake chamber stay x Intake manifold No. 1 air intake chamber stay x Cylinder head EGR valve x intake manifold EGR pipe x Cylinder head Throttle body x Intake manifold Water bypass pipe x Water pump cover Water outlet x Cylinder head WU–TWC x Exhaust manifold Exhaust manifold x Cylinder head Exhaust manifold stay x WU –TWC Exhaust manifold stay x FR engine mounting insulator No. 1 exhaust manifold stay x WU –TWC No. 1 exhaust manifold stay x Cylinder block Main bearing cap x Cylinder block Connecting rod cap x Connecting rod (1 st) Connecting rod cap x Connecting rod (2nd) No. 1 balance shaft housing x No. 2 balance shaft housing (1st) No. 1 balance shaft housing x No. 2 balance shaft housing (2nd) Engine balancer x Cylinder block Rear oil seal retainer x Cylinder block Knock sensor x Cylinder block PS pump bracket x Cylinder block Rear end plate x Cylinder block Flywheel x Crankshaft (M/T) Drive plate x Crankshaft (A/T) RR engine mounting insulator x Cylinder block FR engine mounting insulator x Cylinder block FR engine mounting insulator x Front suspension member RR engine mounting insulator x Front suspension member LH engine mounting insulator x Transaxle PS pump x PS pump bracket Front exhaust pipe x WU –TWC A/C compressor x Cylinder block Fuel inlet hose x Fuel filter (Union bolt) – ENGINE MECHANICAL EG1–145 5S–FE ENGINE – EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS SYSTEM PURPOSE Purpose Abbreviation system Positive crankcase ventilation Fuel evaporative emission control Exhaust gas recirculation Three–way catalytic converter *Multiport fuel injection/Sequential multiport fuel injection PCV EVAP EG R TWC MFI/SFI Reduces blow–by gas (HC) Reduces evaporative HC Reduces NOx Reduces C0, HC and NOx Regulates all engine conditions for reduction of exhaust emissions. ” For inspection and repair of the MFI/SFI system, refer to MFI/SFI Section. PREPARATION SST (SPECIAL SERVICE TOOLS) 09843–18020 Diagnosis Check Wire RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set EQUIPMENT Heater TVV Thermometer TVV Tachometer Torque wrench Vacuum gauge SSM (SPECIAL SERVICE MATERIALS) 08833–00070 Adhesive 1311, THREE BOND 1311 or equivalent ¿¿V EG1–146 5S–FE ENGINE – EMISSION CONTROL SYSTEMS LAYOUT AND SCHEMATIC DRAWING EG1–147 5S–FE ENGINE – EMISSION CONTROL SYSTEMS POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM To reduce HC emission, crankcase blow–by gas is routed through the PCV valve to the air intake chamber for combustion in the cylinders. Engine not Running Normal Operation Idling or Deceleration Acceleration or High Load EG1–148 5S–FE ENGINE – EMISSION CONTROL SYSTEMS PCV VALVE INSPECTION 1. REMOVE PCV VALVE 2. INSTALL CLEAN HOSE TO PCV VALVE 3. BLOW AIR FROM CYLINDER HEAD SIDE Check that air passes through easily. NOTICE: Do not suck air through the valve. Petroleum substances inside the valve are harmful. 4. BLOW AIR FROM AIR INTAKE CHAMBER SIDE Check that air passes through with difficulty. If the PCV valve fails either of the checks, replace it. 5. REMOVE CLEAN HOSE FROM PCV VALVE 6. REINSTALL PCV VALVE PCV HOSES AND CONNECTIONS INSPECTION VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. EG1–149 5S–FE ENGINE – EMISSION CONTROL SYSTEMS EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM To reduce NC emissions, evaporated fuel from the fuel tank is routed through the charcoal canister to the intake manifold for combustion in the cylinders. Engine Coolant Temp. Below 35C (95F) Above 54C (129F) High pressure in tank High vacuum in tank TVV Throttle Valve Opening Canister Check Valve Check Valve In Cap Evaporated Fuel (HC) CLOSED OPEN NC from tank is absorbed into the canister Positioned below port P CLOSED Positioned above port P OPEN HC from canister is led into air intake chamber. OPEN HC from tank is absorbed CLOSED CLOSED into the canister. CLOSED OPEN OPEN Air is led into the fuel tank. EG1–150 5S–FE ENGINE – EMISSION CONTROL SYSTEMS FUEL VAPOR LINES. FUEL TANK AND TANK CAP INSPECTION 1. VISUALLY INSPECT LINES AND CONNECTIONS Look for loosen connections, sharp bends or damage. 2. VISUALLY INSPECT FUEL TANK Look for deformation, cracks or fuel leakage. 3. VISUALLY INSPECT FUEL TANK CAP Check if the cap and/or gasket are deformed or dam– aged. If necessary, repair or replace the cap. CHARCOAL CANISTER INSPECTION 1. REMOVE CHARCOAL CANISTER 2. VISUALLY INSPECT CHARCOAL CANISTER Look for cracks or damage. 3. CHECK FOR CLOGGED FILTER AND STUCK CHECK VALVE (a) Using low pressure compressed air (4.71 kPa, 48 gf/cm2, 0.68 psi), blow into port A and check that air flows without resistance from the other ports. (b) Blow air (4.71 kPa, 48 gf/cm
, 0.68 psi) into port B and check that air does not flow from the other ports. If a problem is found, replace the charcoal canister. 4. CLEAN FILTER IN CANISTER Clean the filter by blowing 294 kPa (3 kgf/cm
, 43 psi) of compressed air into port A while holding port B closed. NOTICE: • Do not attempt to wash the canister. • No activated carbon should come out. 5. REINSTALL CHARCOAL CANISTER EG1–151 5S–FE ENGINE – EMISSION CONTROL SYSTEMS TVV INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE TVV FROM WATER INLET HOUSING (a) Disconnect the following hoses: (1) Vacuum hose (from throttle body) (2) Vacuum hose (from charcoal canister) (b) Remove the TVV. 3. INSPECT TVV OPERATION (a) Cool the TVV to below 35C (95F) with cool water. (b) Check that air does not flow from the upper port to lower port. (c) Heat the TVV to above 54C (129F) with hot water. (d) Check that air flows from the upper port to lower port. If operation is not as specified, replace the TVV. 4. REINSTALL TVV (a) Apply adhesive to 2 or 3 threads of the TVV, and install it. Adhesive: Part No. 08833–00070, THREE BOND 1324 or equivalent Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) (b) Reconnect 2 vacuum hoses. 5. REFILL WITH ENGINE COOLANT CHECK VALVE INSPECTION INSPECT CHECK VALVE (a) Check that air flows from the yellow port to the black port. (b) Check that air does not flow from the black port to the yellow port. If operation is not as specified, replace the check valve. EG1–152 5S–FE ENGINE – EMISSION CONTROL SYSTEMS EXHAUST GAS RECIRCULATION (EGR) SYSTEM EG1–153 5S–FE ENGINE – EMISSION CONTROL SYSTEMS EGR SYSTEM INSPECTION 1. CHECK AND CLEAN FILTER IN EGR VACUUM MODULATOR (a) Check the filter for contamination or damage. (b) Using compressed air, clean the filter. HINT: Install the filter with the coarser surface facing the atmospheric side (outward). 2. PREPARATION Using a 3–way connector, connect a vacuum gauge to the hose between the EGR valve and VSV. 3. CHECK SEATING OF EGR VALVE Start the engine and check that the engine starts and runs at idle. 4. CONNECT TERMINALS TE1 AND E1 Using SST, connect terminals TE 1 and E 1 of the data link connector 1. SST 09843–18020 5. CHECK VSV (a) The engine coolant temperature should be below 60
C (140
F) (A/T) or 55
C (131
F) (M/T). (b) Check that the vacuum gauge indicates zero at 2.500 rpm. 6. CHECK VSV AND EGR VACUUM MODULATOR WITH HOT ENGINE (a) Warm up the engine. (b) Check that the vacuum gauge indicates low vacuum at 2,500 rpm. EG1–154 5S–FE ENGINE – EMISSION CONTROL SYSTEMS (c) Disconnect the vacuum hose port R of the EGR vacuum modulator and connect port R directly to the intake manifold with another hose. (d) Check that the vacuum gauge indicates high vacuum at 2,500 rpm. HINT: As a large amount of exhaust gas enters, the engine will misfire slightly. (e) Remove the vacuum gauge, and reconnect the vacuum hoses to the proper locations. 7. CHECK EGR VALVE (a) Apply vacuum directly to the EGR valve with the engine idling. (b) Check that the engine runs rough or dies. (c) Reconnect the vacuum hoses to the proper locations. 8. DISCONNECT TERMINALS TE1 AND E1 Remove the SST. SST 09843–18020 IF NO PROBLEM IS FOUND WITH THIS INSPECTION, SYSTEM IS NORMAL; OTHERWISE INSPECT EACH PART VSV INSPECTION (California) 1. REMOVE VSV (a) Disconnect the following connectors and hoses: (1) VSV for EGR (A) connector (2) VSV for fuel pressure control (B) connector (3) Vacuum hose (from EGR valve) from port E of VSV (A) (4) Vacuum hose (from port “a” of EGR vacuum modulator) from port G of VSV (A) (5) Vacuum hose (from fuel pressure regulator) from port E of VSV (B) (6) Vacuum hose (from air intake chamber) from port G of VSV (B) (b) Remove the bolt and VSV assembly. EG1–155 5S–FE ENGINE – EMISSION CONTROL SYSTEMS 2. INSPECT VSV A. Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance (Cold): 33–39
If there is no continuity, replace the VSV. B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. C. Inspect VSV operation (a) Check that air flows from port E to port G. (b) Apply battery voltage across the terminals. (c) Check that air flows from port E to the filter. If operation is not as specified, replace the VSV. 3. REINSTALL VSV VSV INSPECTION (Except California) 1. REMOVE VSV (a) Disconnect the following connector and hoses: (1) VSV connector (2) Vacuum hose (from EGR valve) from port E of VSV (3) Vacuum hose (from port “Q” of EGR vacuum modulator) from port G of VSV EG1–156 5S–FE ENGINE – EMISSION CONTROL SYSTEMS (b) Remove the bolt and VSV. 2. INSPECT VSV A. Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance (Cold): 33–39
If there is no continuity, replace the VSV. B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. C. Inspect VSV operation (a) Check that air flows from port E to port G. (b) Apply battery voltage across the terminals. (c) Check that air flows from port E to the filter. If operation is not as specified, replace the VSV. 3. REINSTALL VSV EG1–157 5S–FE ENGINE – EMISSION CONTROL SYSTEMS EGR VACUUM MODULATOR INSPECTION CHECK EGR VACUUM MODULATOR OPERATION (a) Disconnect the vacuum hoses from ports P, Q and R of the EGR vacuum modulator. (b) Block ports P and R with your finger. (c) Blow air into port Q, and check that the air passes through to the air filter side freely. (d) Start the engine, and maintain speed at 2.500 rpm. (e) Repeat the above test. Check that there is a strong resistance to air flow. (f) Reconnect the vacuum hoses to the proper locations. EGR VALVE INSPECTION 1. REMOVE EGR VALVE Check for sticking and heavy carbon deposits. If a problem is found, replace the valve. 2. REINSTALL EGR VALVE WITH NEW GASKET Nut Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) Union nut Torque: 59 N–m (600 kgf–cm, 43 ft–lbf) EG1–158 5S–FE ENGINE – EMISSION CONTROL SYSTEMS THREE–WAY CATALYTIC CONVERTER (TWC) SYSTEM To reduce C0, HC end NOx emissions, they are oxidized, reduced and converted to carbon dioxide (CO2), water (H20) and nitrogen (N2) by the catalyst. Exhaust Port WU–TWC TWC Exhaust Gas EXHAUST PIPE ASSEMBLY INSPECTION 1. CHECK CONNECTIONS FOR LOOSENESS OR DAMAGE 2. CHECK CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE THREE–WAY CATALYTIC CONVERTER INSPECTION TWC: CHECK FOR DENTS OR DAMAGE If any part of protector is damaged or dented to the extent that it contacts the TWC, repair or replace it. EG1–159 5S–FE ENGINE – EMISSION CONTROL SYSTEMS HEAT INSULATOR INSPECTION TWC: 1. CHECK HEAT INSULATOR FOR DAMAGE 2. CHECK FOR ADEQUATE CLEARANCE BETWEEN THREE – WAY CATALYTIC CONVERTER AND HEAT INSULATOR THREE–WAY CATALYTIC CONVERTER REPLACEMENT WU–TWC: 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE FRONT EXHAUST PIPE (a) Loosen the 2 bolts, and disconnect the bracket. (b) Remove the 2 bolts and nuts holding the front exhaust pipe to the center exhaust pipe. (c) Using a 14 mm deep socket wrench, remove the 3 nuts holding the front exhaust pipe to the WU–TWC. (d) Remove the front exhaust pipe and gaskets. 3. REMOVE WARM UP THREE – WAY CATALYTIC CONVERTER (a) Check that the WU–TWC is cool. (b) Disconnect the sub oxygen sensor connector. (c) Remove the bolt, nut and No. 1 manifold stay. EG1–160 5S–FE ENGINE – EMISSION CONTROL SYSTEMS (d) Remove the bolt, nut and manifold stay. (e) Remove the 3 bolts, 2 nuts, WU –TWC, gasket, re– tainer and cushion. (f) Remove the 8 bolts and 2 heat insulators from the WU –TWC. 4. REINSTALL WARM–UP THREE–WAY CATALYTIC CONVERTER (a) Install the 2 heat insulators to a new WU –TWC with the 8 bolts. (b) Place new cushion, retainer and gasket on the WU– TWC. (c) Install the WU–TWC with the 3 bolts and 2 new nuts. Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) EG1–161 5S–FE ENGINE – EMISSION CONTROL SYSTEMS (d) Install the manifold stay with the bolt and nut. Torque: 42 N–m (425 kgf–cm. 31 ft–lbf) (e) Install the No. 1 manifold stay with the bolt and nut. Torque: 42 N–m (425 kgf–cm. 31 ft–lbf) (f) Connect the sub oxygen sensor connector. 5. REINSTALL FRONT EXHAUST PIPE (a) Place 2 new gaskets on the front and rear of the front exhaust pipe. (b) Temporarily install the 2 bolts and 2 new nuts holding the front exhaust pipe to the center exhaust pipe. (c) Using a 14 mm deep socket wrench, install the 3 new nuts holding the front exhaust pipe to the WU –TWC. Torque: 62 N–m (630 kgf–cm, 46 ft–lbf) (d) Tighten the 2 bolts and nuts holding the front exhaust pipe to the center exhaust pipe. Torque: 58 N–m (570 kgf–cm, 41 ft–lbf) (e) Install the bracket with the 2 bolts. 6. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG1–162 5S–FE ENGINE – EMISSION CONTROL SYSTEMS TWC: 1. REMOVE FRONT EXHAUST PIPE (THREE – WAY CATALYTIC CONVERTER) (a) Loosen the 2 bolts, and disconnect the bracket. (b) Remove the 2 bolts and nuts holding the front exhaust pipe to the center exhaust pipe. (c) Using a 14 mm deep socket wrench, remove the 3 nuts holding the front exhaust pipe to the WU–TWC. (d) Remove the front exhaust pipe and gasket. 2. REINSTALL FRONT EXHAUST PIPE (THREE–WAY CATALYTIC CONVERTER) (a) Place 2 new gaskets on the front and rear of the front exhaust pipe. (b) Temporarily install the 2 bolts and 2 new nuts holding the front exhaust pipe to the center exhaust pipe. (c) Using a 14 mm deep socket wrench, install the 3 new nuts holding the front exhaust pipe to the WU –TWC. Torque: 412 N–m (630 kgf–cm, 46 ft–lbf) (d) Tighten the 2 bolts and nuts holding the front exhaust pipe to the center exhaust pipe. Torque: 58 N–m (570 kgf–cm, 41 ft–lbf) (e) Install the bracket with the 2 bolts. EG1–163 5S–FE ENGINE SERVICE SPECIFICATIONS SERVICE DATA VSV (for EGR) Resistance TORQUE SPECIFICATIONS Part tightened TVV x Water outlet housing EGR valve x Intake manifold EG R valve x EGR pipe WU–TWC x Exhaust manifold Exhaust manifold stay x WU–TWC Exhaust manifold stay x FR engine mounting insulator No.1 exhaust manifold stay x WU–TWC No.1 exhaust manifold stay x Cylinder block Front exhaust pipe x WU–TWC Front exhaust pipe x Center exhaust pipe – EMISSION CONTROL SYSTEMS EG1–164 5S–FE ENGINE MFI/SFI SYSTEM DESCRIPTION – MFI/SFI SYSTEM EG1–165 5S–FE ENGINE Except California (MFI System) – FE ENGINE – MFI/SFI SYSTEM EG1–166 5S–FE ENGINE – MFI/SFI SYSTEM The MFI (Multiport Fuel Injection)/SFI (Sequential Multiport Fuel Injection) system is composed of 3 basic sub–systems: Fuel, Air Induction and Electronic Control Systems. FUEL SYSTEM Fuel is supplied under constant pressure to the MFI/SFI injectors by an electric fuel pump. The injectors inject a metered quantity of fuel into the intake port in accordance with signals from the ECM (Engine Control Module). AIR INDUCTION SYSTEM The air induction system provides sufficient air for engine operation. ELECTRONIC CONTROL SYSTEM The CAMRY 5S–FE engine is equipped with a TOYOTA Computer Controlled System (TCCS) which centrally controls the MFI/SFI, ESA, IAC diagnosis systems etc. by means of an Engine Control Module (ECM–formerly MFI/SFI computer) employing a microcomputer. The ECM controls the following functions: 1. Multiport Fuel Injection (MFI)/Sequential Multiport Fuel Injection (SFI) The ECM receives signals from various sensors indicating changing engine operation conditions such as: Intake manifold pressure Intake air temperature Engine coolant temperature Engine speed Throttle valve opening angle Exhaust oxygen content etc. The signals are utilized by the ECM to determine the injection duration necessary for an optimum air–fuel ratio. 2. Electronic Spark Advance (ESA) The ECM is programmed with data for optimum ignition timing under all operating conditions. Using data provided by sensors which monitor various engine functions (RPM, engine coolant temperature, etc.), the microcomputer (ECM) triggers the spark at precisely the right instant. 3. Idle Air Control (IAC) The ECM is programmed with target idling speed values to respond to different engine conditions (engine coolant temperature, air conditioning ON/OFF, etc.). Sensors transmit signals to the ECM which controls the flow of air through the bypass of the throttle valve and adjusts idle speed to the target value. 4. Diagnosis The ECM detects any malfunctions and abnormalities in the sensor network and lights a malfunction indicator lamp in the combination meter. At the same time, trouble is identified and a diagnostic trouble code is recorded by the EC 5. The diagnostic trouble code can be read by the number of blinks of the malfunction indicator lamp when terminals TE1 and E1 are connected. The diagnostic trouble codes are referred to in later page. (See page EG1–300) Fail–Safe Function In the event of the sensor malfunction, a back–up circuit will take over to provide minimal driveability, and the malfunction indicator lamp will illuminate. EG1–167 5S–FE ENGINE – MFI/SFI SYSTEM OPERATION FUEL SYSTEM Fuel pumped up by the fuel pump, flows through the fuel filter and is distributed to each injector at a set pressure maintained by the pressure regulator. The fuel pressure regulator adjusts the pressure of the fuel from the fuel line (high pressure side) to a pressure 284 kPa (2.9 kgf/cm
, 41 psi) higher than the pressure inside the cylinder head, and excess fuel is returned to the fuel tank through the return pipe. The pulsation damper absorbs the slight fluctuations in fuel pressure caused by fuel injector from the injector. The injectors operate on input of injection signals from the ECM and inject fuel into the cylinder head. EG1–168 5S–FE ENGINE – MFI/SFI SYSTEM AIR INDUCTION SYSTEM Air is filtered through the air cleaner and the amount flowing to the air intake chamber is determined according to the throttle valve opening in the throttle body and the engine speed. Intake air controlled by the throttle valve opening is distributed from the air intake chamber to the manifold of each cylinder and is drawn into the combustion chamber. At low temperatures the IAC valve opens and the air flows through the IAC valve and the throttle body, into the air intake chamber. During engine warming up, even if the throttle valve is completely closed, air flows to the air intake chamber, thereby increasing the idle speed (first idle operation). The air intake chamber prevents pulsation of the intake air. It also prevents intake air interference in each cylinder. EG1–169 5S–FE ENGINE – MFI/SFI SYSTEM ELECTRONIC CONTROL SYSTEM The control system consists of sensors which detect various engine conditions, and a ECM which determines the injection volume (timing) based on the signals from the sensors. The various sensors detect the intake air pressure, engine speed, oxygen density in the exhaust gas, engine coolant temperature, intake air temperature and atmospheric pressure etc. and convert the information into an electrical signal which. is sent to the ECM. Based on these signals, the ECM calculates the optimum ignition timing for the current conditions and operates the injectors. The ECM not only controls the fuel injection timing, but also the self diagnostic function which records the occurrence of a malfunction, ignition timing control, idle speed control and EGR control. EG1–170 5S–FE ENGINE – MFI/SFI SYSTEM PREPARATION SST (SPECIAL SERVICE TOOLS) 09268–41045 Injection Measuring Tool Set (09268–41080) No.6 union (09268–41090) No.7 union (90405–09015) No.1 Union 09268–45012 EFI Fuel Pressure Gauge 09631–22020 Power Steering Hose Nut 14 x 17 mm Wrench Set Fuel line flare nut 09842–30070 Wiring “F” EFI Inspection 09843–18020 Diagnosis Check Wire RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set 09200–00010 Engine Adjust Kit 09258–00030 Hose Plug Set Plug for vacuum hose, fuel hose etc. EG1–171 5S–FE ENGINE – MFI/SFI SYSTEM EQUIPMENT Carburetor cleaner Throttle body Graduated cylinder Injector Soft brush Throttle body Sound scope Injector Tachometer Torque wrench Vacuum gauge EG1–172 5S–FE ENGINE – MFI/SFI SYSTEM PRECAUTION 1. Before working on the fuel system, disconnect the negative (–) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the computer will be erased when the battery terminal is removed. Therefore, if necessary, read the diagnosis before removing the terminal. CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. Do not smoke or work near an open flame when working on the fuel system. 3. Keep gasoline away from rubber or leather parts. MAINTENANCE PRECAUTIONS 1. CHECK CORRECT ENGINE TUNE–UP (See page EG1–8) 2. PRECAUTION WHEN CONNECTING GAUGE (a) Use battery as the power source for the timing light, tachometer, etc. (b) Connect the tester probe of a tachometer to the termi– nal IGE) of the data link connector 1. 3. IN EVENT OF ENGINE MISFIRE, FOLLOWING PRECAUTIONS SHOULD BE TAKEN (a) Check proper connection of battery terminals, etc. (b) Handle high–tension cords carefully. (c) After repair work, check that the ignition coil termi– nals and all other ignition system lines are reconne– cted securely. (d) When cleaning the engine compartment, be especially careful to protect the electrical system from water. 4. PRECAUTIONS WHEN HANDLING OXYGEN SENSOR (a) Do not allow oxygen sensor to drop or hit against an object. (b) Do not allow the sensor to come into contact with water. EG1–173 5S–FE ENGINE – MFI/SFI SYSTEM IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYSTEM (HAM, CB, ETC.) If the vehicle is equipped with a mobile communica– tion system, refer to the precaution in the IN section. AIR INDUCTION SYSTEM 1. Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run out of tune. 2. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run out of tune. ELECTRONIC CONTROL SYSTEM 1. Before removing MFI/SFI wiring connectors, termi– nals, etc., first disconnect the power by either turning the ignition switch OFF or disconnecting the battery terminals. HINT: Always check the diagnostic trouble code before disconnecting the negative (–) terminal cable from the battery. 2. When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative (–) cables. 3. Do not permit parts to receive a severe impact during removal or installation. Handle all MFI/SFI parts care– fully, especially the ECM. 4. Do not be careless during troubleshooting as there are numerous transistor circuits and even slight terminal contact can further troubles. 5. Do not open the ECM cover. 6. When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting on the MFI/SFI parts and wiring connectors. 7. Parts should be replaced as an assembly. EG1–174 5S–FE ENGINE – MFI/SFI SYSTEM 8. Care is required when pulling out and inserting wiring connectors. (a) Release the lock and pull out the connector, pulling on the connectors. (b) Fully insert the connector and check that it is locked. 9. When inspecting a connector with a volt/ohmmeter. (a) Carefully take out the water–proofing rubber if it is a water–proof type connector. (b) Insert the test probe into the connector from wiring side when checking the continuity, amperage or volt– age. (c) Do not apply unnecessary force to the terminal. (d) After checking, install the water–proofing rubber on the connector securely. 10. Use SST for inspection or test of the injector or its wiring connector. SST 09842–30070 EG1–175 5S–FE ENGINE – MFI/SFI SYSTEM FUEL SYSTEM 1. When disconnecting the high pressure fuel line, a large amount of gasoline will spill out, so observe the following procedures: (a) Put a container under the connection. (b) Slowly loosen the connection. (c) Disconnect the connection. (d) Plug the connection with a rubber plug. 2. When connecting the flare nut or union bolt on the high pressure pipe union, observe the following proce– dures: Union Bolt Type: (a) Always use a new gasket. (b) Tighten the union bolt by hand. (c) Tighten the union bolt to the specified torque. Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) Flare Nut Type: (s) Apply alight coat of engine oil to the flare and tighten the flare nut by hand. (b) Using SST, torque the flare nut. SST 09631–22020 Torque: 28 N–m (285 kgf–cm, 21 ft–lbf) for fuel pump side 30 N–m (310 kgf–cm, 22 ft–lbf) for others HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). 3. Observe the following precautions when removing and installing the injectors. (a) Never reuse the O–ring. (b) When placing a new O–ring on the injector, take care not to damage it in any way. (c) Coat a new 0– ring with spindle oil or gasoline before installing–never use engine, gear or brake oil. 4. Install the injector to delivery pipe and intake manifold as shown in the illustration. EG1–176 5S–FE ENGINE – MFI/SFI SYSTEM 5. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system. (a) Using SST, connect terminals + B and FP of the data link connector 1. SST 09843–18020 (b) With engine stopped, turn the ignition switch ON. (c) Pinch the fuel return hose. The pressure in high pres– sure line will rise to approx. 392 kPa (4kgf/cm2, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTICE: Always pinch the hose. Avoid bending as it may cause the hose to crack. (d) Turn the ignition switch OFF. (9) Remove the SST. SST 09843–18020 EG1–177 5S–FE ENGINE – MFI/SFI SYSTEM FUEL PUMP SYSTEM CIRCUIT ON–VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION (a) Using SST; connect terminals +B and FP of the data link connector 1. SST 09843–18020 (b) Turn the ignition switch ON. NOTICE: Do not start the engine. EG1–178 5S–FE ENGINE – MFI/SFI SYSTEM (c) Check that there is pressure in the hose from the fuel filter. HINT: At this time, you will hear fuel return noise. (d) Turn the ignition switch OFF. (e) Remove the SST. SST 09843–18020 If • • • • • there is no pressure, check the following parts: Fusible link Fuses (AM2 30A, EFI 15A, IGN 7.5A) EFI main relay Fuel pump Wiring connections 2. CHECK FUEL PRESSURE (a) Check that the battery voltages is above 12 volts. (b) Disconnect the negative (–) terminal cable from the battery. CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is discon– nected from the battery. EG1–179 5S–FE ENGINE – MFI/SFI SYSTEM (c) Put a suitable container or shop towel under the fuel filter. (d) Remove the union bolt and 2 gaskets, and disconnect the fuel inlet hose from the fuel filter outlet. HINT: Slowly loosen the union bolt. (e) Install the fuel inlet hose and SST (pressure gauge) to the fuel filter outlet with 3 new gaskets and the union bolt. SST 09268–45012 Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) (f) Wipe off any splattered gasoline. (g) Reconnect the battery negative (–) cable. (h) Using SST, connect terminals +B and FP of the data link connector 1. SST 09843–18020 (i) Turn the ignition switch ON. Measure the fuel pressure. Fuel pressure: 265 – 304 kPa (2.7 – 3.1 kgf/cm
, 38 – 44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the following parts: • Fuel hoses and connections • Fuel pump • Fuel filter • Fuel pressure regulator EG1–180 5S–FE ENGINE – MFI/SFI SYSTEM (k) Remove the SST. SST 09483–18020 (l) Start the engine. (m) Disconnect the vacuum sensing hose from the air intake chamber and plug the air intake chamber outlet. (n) Measure the fuel pressure at idle. Fuel pressure: 265 – 304 kPa (2.7 – 3.1 kgf/cm
, 38 – 44 psi) (o) Reconnect the vacuum sensing hose to the air intake chamber. (p) Measure the fuel pressure at idle. Fuel pressure: 206 – 255 kPa (2.1 – 2.6 kgf/cm
, 31 – 37 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. (q) Stop the engine. (r) Check that the fuel pressure remains 147 kPa (1.5 kgf/cm2, 21 psi) or more for 5 minutes after the engine is turned off. If pressure is not as specified, check the fuel pump, pressure regulator and/or injector. (s) After checking fuel pressure, disconnect the battery negative (–) cable and carefully remove the SST to prevent gasoline from splashing. SST 09268–45012 (t) Connect the fuel inlet hose with 2 new gaskets and the union bolt. Torque: 29 N–m (300 kgf–cm. 22 ft–lbf) (u) Reconnect the cable to the negative (–) terminal of the battery. (v) Check for fuel leakage. EG1–181 5S–FE ENGINE – MFI/SFI SYSTEM FUEL PUMP INSPECTION 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the Ignition switch Is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE REAR SEAT CUSHION 3. DISCONNECT FUEL PUMP & SENDER GAUGE CON– NECTOR 4. INSPECT FUEL PUMP A. Inspect fuel pump resistance Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance (Cold): 0.2–3.0 Ω If the resistance is not as specified, replace the fuel pump. B. Inspect fuel pump operation Connect the positive (+) lead from the battery terminal 4 of the connector, and the negative (–) lead to terminal 5. Check that the fuel pump operates. NOTICE: • These tests must be performed quickly (within 10 seconds) to prevent the coil from burning out. • Keep the fuel pump a: far away from the battery as possible. • Always perform switching at the battery side. If operation is not as specified, replace the fuel pump. 5. RECONNECT FUEL PUMP & SENDER GAUGE CONNECTOR 6. INSTALL REAR SEAT CUSHION 7. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG1–182 5S–FE ENGINE – MFI/SFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION FUEL PUMP REMOVAL CAUTION: Do not smoke or work near an open flame when working on the fuel pump. 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE REAR SEAT CUSHION EG1–183 5S–FE ENGINE – MFI/SFI SYSTEM 3. REMOVE FLOOR SERVICE HOLE COVER (a) Disconnect the fuel pump connector. (b) Remove the 5 screws and service hole cover. 4. REMOVE FUEL PUMP LEAD WIRE 5. DISCONNECT FUEL PIPE AND HOSE FROM FUEL PUMP BRACKET CAUTION: Remove the fuel filter cap to prevent the fuel from flowing out. (a) Using SST, disconnect the outlet pipe from the pump bracket. SST 09631–22020 (b) Disconnect the return hose from the pump bracket. 6. REMOVE FUEL PUMP BRACKET ASSEMBLY FROM FUEL TANK (a) Remove the 8 bolts. (b) Pull out the pump bracket assembly. (c) Remove the gasket from the pump bracket. EG1–184 5S–FE ENGINE – MFI/SFI SYSTEM COMPONENTS FOR DISASSEMBLY AND ASSEMBLY FUEL PUMP DISASSEMBLY 1. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET (a) Remove the fuel pump lead wire. (b) Pull off the lower side of the fuel pump from the pump bracket. (c) Disconnect the fuel hose from the fuel pump, and remove the fuel pump. (d) Remove the rubber cushion from the fuel pump. 2. REMOVE FUEL SENDER GAUGE FROM FUEL PUMP BRACKET (a) Disconnect the fuel sender gauge connector. (b) Remove the 2 screws and sender gauge. EG1–185 5S–FE ENGINE – MFI/SFI SYSTEM 3. REMOVE FUEL PUMP FILTER FROM FUEL PUMP (a) Using a small screwdriver, remove the clip. (b) Pull out the pump filter. 4. REMOVE CONNECTOR Remove the 2 screws, connector support, connector and gasket. FUEL PUMP ASSEMBLY (See Components for Disassembly and Assembly) 1. INSTALL CONNECTOR Install the gasket, connector and connector support with the 2 screws. 2. INSTALL FUEL PUMP FILTER TO FUEL PUMP Install the pump filter with a new clip. 3. INSTALL FUEL SENDER GAUGE TO FUEL PUMP BRACKET (a) Install the sender gauge with the 2 screws. (b) Connect the fuel sender gauge connector. 4. INSTALL FUEL PUMP TO FUEL PUMP BRACKET (a) Install the rubber cushion to the fuel pump. (b) Connect the fuel hose to the outlet port of the fuel pump. (c) Install the fuel pump by pushing the lower side of the fuel pump. (d) Install the fuel pump connector. EG1–186 5S–FE ENGINE – MFI/SFI SYSTEM FUEL PUMP INSTALLATION (See Components for Removal and Installation) 1. INSTALL FUEL PUMP BRACKET ASSEMBLY TO FUEL TANK (a) Install a new gasket to the pump bracket. (b) Insert the pump bracket assembly into the fuel tank. (c) Install the pump bracket with the 8 screws. Torque: 3.9 N–m (40 kgf–cm, 35 in.–Ibf) 2. CONNECT FUEL PIPE AND HOSE TO FUEL PUMP BRACKET (a) Using SST, connect the outlet pipe to the pump bracket. SST 09631–22020 Torque: 28 N–m (285 kgf–cm, 21 ft–lbf) (b) Connect the return hoses to the pump bracket. 3. CHECK FOR FUEL LEAKAGE (See page EG1–176) 4. CONNECT FUEL PUMP LEAD WIRE 5. INSTALL FLOOR SERVICE HOLE COVER (a) Install the service hole cover with the 5 screws. (b) Connect the fuel pump (with fuel sender gauge) connector. 6. INSTALL REAR SEAT CUSHION 7. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG1–187 5S–FE ENGINE – MFI/SFI SYSTEM FUEL PRESSURE REGULATOR ON–VEHICLE INSPECTION INSPECT FUEL PRESSURE (See page EG1–178) COMPONENTS FOR REMOVAL AND INSTALLATION FUEL PRESSURE REGULATOR REMOVAL 1. DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR 2. DISCONNECT FUEL RETURN PIPE FROM FUEL PRESSURE REGULATOR (a) Put a suitable container or shop rag under the pres– sure regulator. (b) Remove the union bolt and 2 gaskets, and disconnect the return pipe from the pressure regulator. HINT: Slowly loosen the union bolt. EG1–188 5S–FE ENGINE – MFI/SFI SYSTEM 3. REMOVE FUEL PRESSURE REGULATOR (a) Remove the 2 bolts, and pull out the pressure regula– tor. (b) Remove the O–ring from the pressure regulator. FUEL PRESSURE REGULATOR INSTALLATION (See Components for Removal and Installation) 1. INSTALL FUEL PRESSURE REGULATOR (a) Apply a light coat of gasoline to a new O–ring, and install it to the pressure regulator. (b) Install the pressure regulator with the 2 bolts. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) 2. CONNECT FUEL RETURN PIPE TO FUEL PRESSURE REGULATOR Install the return pipe with 2 new gaskets and the union bolt. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) 3. CONNECT VACUUM SENSING HOSE TO FUEL PRESSURE REGULATOR 4. CHECK FOR FUEL LEAKAGE (See page EG1–176) EG1–189 5S–FE ENGINE – MFI/SFI SYSTEM INJECTOR ON–VEHICLE INSPECTION 1. INSPECT INJECTOR OPERATION Check operation sound from each injector. (a) With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine speed. (b) If you have no sound scope, you can check the injec– tor transmission operation with your finger. If no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the ECM. 2. INSPECT INJECTOR RESISTANCE (a) Disconnect the injector connector. (b) Using an ohmmeter, measure the resistance between the terminals. Resistance: Approx. 13.8
If the resistance is not as specified, replace the injector. (c) Reconnect the injector connector. EG1–190 5S–FE ENGINE – MFI/SFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION EG1–191 5S–FE ENGINE – MFI/SFI SYSTEM INJECTORS REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch i: turned to the “LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. DRAIN ENGINE COOLANT 3. A/T: DISCONNECT THROTTLE CABLE FROM THROTTLE BODY 4. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY 5. REMOVE AIR CLEANER CAP, RESONATOR AND AIR CLEANER HOSE (a) Disconnect the intake air temperature sensor connector. (b) California only: Disconnect the air hose from the air cleaner hose. (c) Loosen the air cleaner hose clamp bolt. (d) Disconnect the 4 air cleaner cap clips. (e) Disconnect the air cleaner hose from the throttle body, and remove the air cleaner cap together with the resonator and air cleaner hose. 6. REMOVE THROTTLE BODY (a) Disconnect throttle position sensor connector. (b) Disconnect IAC valve connector. EG1–192 5S–FE ENGINE – MFI/SFI SYSTEM (c) Disconnect the following hoses from the throttle body. (1) PCV hose (2) 2 vacuum hoses from EGR vacuum modulator (3) Vacuum hose from TVV (for EVAP) (d) Type A: Remove the 4 bolts. (e) Type B: Remove the 2 bolts and 2 nuts. (f) Disconnect the following hoses from the throttle body, and remove the throttle body. (1) Water bypass hose from water outlet (2) Water bypass hose from water bypass pipe (3) California: Air hose from cylinder head Except California: Air hose from air tube 7. DISCONNECT PS VACUUM HOSES 8. DISCONNECT VACUUM HOSES FROM TVV (FOR EVAP) EG1–193 5S–FE ENGINE – MFI/SFI SYSTEM 9. REMOVE EGR VALVE AND VACUUM MODULATOR (a) Disconnect the EGR gas temperature sensor connector. (b) Disconnect the following hoses: (1) 2 vacuum hoses from VSV (for EGR) (2) Vacuum hose from charcoal canister (c) Disconnect the vacuum hose clamp. (d) Loosen the union nut of the EGR pipe, and remove the 2 nuts, the EGR valve, vacuum modulator, vacuum hoses assembly and gasket. 10. DISCONNECT VACUUM HOSES Disconnect the following hoses: (1) MAP sensor hose from air intake chamber (2) Brake booster vacuum hose from air intake chamber (3) Vacuum sensing hose from fuel pressure regulator 11. w/ A/C: DISCONNECT A/C IDLE–UP VALVE CONNECTOR 12. DISCONNECT 2 ENGINE WIRE GROUND STRAPS FROM INTAKE MANIFOLD 13. DISCONNECT KNOCK SENSOR AND VSV (FOR EGR) CONNECTORS 14. CALIFORNIA ONLY: DISCONNECT VSV (FOR FUEL PRESSURE CONTROL) CONNECTOR AND VACUUM HOSES 15. REMOVE BOLT AND WIRE CLAMP, AND DISCON– NECT ENGINE WIRE HARNESS 16. REMOVE INTAKE MANIFOLD (a) Remove the 4 bolts, wire bracket, No.1 air intake chamber and manifold stays. EG1–194 5S–FE ENGINE – MFI/SFI SYSTEM (b) Remove the 6 bolts, 2 nuts, intake manifold and gasket. (c) Disconnect the 2 wire clamps from the wire brackets on the intake manifold. 17. DISCONNECT INJECTOR CONNECTORS 18. REMOVE DELIVERY PIPE AND INJECTORS (a) Loosen the pulsation damper, and disconnect the fuel inlet pipe. (b) Disconnect the fuel return hose. (c) Remove the 2 bolts and delivery pipe together with the 4 injectors. NOTICE: Be careful not to drop the injectors when rem– oving the delivery pipe. (d) Remove the 4 insulators (except California) and 2 spacers from the cylinder head. (e) Pull out the 4 injectors from the delivery pipe. EG1–195 5S–FE ENGINE – MFI/SFI SYSTEM (f) California: Remove the 2 O–rings, insulator and grommet from each injector. (g) Except California: Remove the O–ring and grommet from each injector. INJECTORS INSPECTION 1. INSPECT INJECTOR INJECTION CAUTION: Keep injector clear of sparks during the test. (a) Disconnect the fuel hose from the fuel filter outlet. (b) Connect SST (union and hose) to the fuel filter outlet with 2 new gaskets and union bolts. SST 09268–41045 (90405–09015) Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) HINT: Use the vehicle’s fuel filter. (c) Install a new O–ring to the fuel inlet of pressure regulator. (d) Connect SST (hose) to the fuel inlet of the pressure regulator with SST (union) and the 2 bolts. SST 09268–41045 (09268–41090) Torque: 5.4 N–m (55 kgf–cm, 48 ft–lbf) (e) Connect the fuel return hose to the fuel outlet of the pressure regulator with SST (union), 2 new gaskets and union bolts. EG1–196 5S–FE ENGINE – MFI/SFI SYSTEM SST 09268–41045 (09268–41080) Torque: 18 N–m (180 kgf–cm, 13 ft–lbf) (f) Install the grommet and a new O–ring to the injector. (g) Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268–41045 (h) Put the injector into a graduated cylinder. HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. (i) Using SST, connect terminals +B and FP of the data link connector 1. SST 09843–18020 (j) Reconnect the negative (–) terminal cable to the battery. (k) Turn the ignition switch ON. NOTICE: Do not start the engine. (l) Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842–30070 Volume: 49 – 59 cm
(3.0–3.6 cu in.) per 15 sec. Difference between each Injector: 5 cm
(0.3 cu in.) or less If the injection volume is not as specified, replace the injector. 2. INSPECT LEAKAGE (a) In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842–30070 Fuel drop: One drop or less per minute (b) Disconnect the negative (–) terminal cable from the battery. (c) Remove the SST. SST 09268–41045 and 09843–18020 EG1–197 5S–FE ENGINE – MFI/SFI SYSTEM INJECTORS INSTALLATION (See Components for Removal and Installation) 1. INSTALL INJECTORS AND DELIVERY PIPE (a) California: Install new insulator and grommet to each injector. (b) Except California: Install a new grommet to each injector. (c) California: Apply a light coat of gasoline to 2 new O–rings, and install them to each injector. (d) Except California: Apply a light coat of gasoline to a new O–ring, and install it to each injector. (e) While turning the injector left and right, install it to the delivery pipes. Install the 4 injectors. (f) Install the following parts to the cylinder head: (1) 2 spacers (2) Except California: 4 new insulators (g) Place the 4 injectors together with the delivery pipe in position on the cylinder head. (h) Temporarily install the 2 bolts holding the delivery pipe to the cylinder head. EG1–198 5S–FE ENGINE – MFI/SFI SYSTEM (i) Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O – rings. Replace the O–rings. (j) Position the injector connector upward. (k) Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) (l) Connect the fuel return hose. (m) Connect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the pulsation damper. Torque: 34 N–m (350 kgf–cm, 25 ft–lbf) 2. CONNECT INJECTOR CONNECTORS 3. INSTALL INTAKE MANIFOLD (a) Connect the 2 wire clamps to the wire brackets on the intake manifold. EG1–199 5S–FE ENGINE – MFI/SFI SYSTEM (b) Install a new gasket and the intake manifold with the 6 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) (c) Install the No. 1 air intake chamber and manifold stays, wire bracket with the 4 bolts. 14 mm head bolt Torque: 42 N–m (425 kgf–cm, 31 ft–lbf) 12 mm head bolt Torque: 22 N–m (220 kgf–cm, 16 ft–lbf) 4. CONNECT ENGINE WIRE HARNESS WITH WIRE CLAMP AND BOLT 5. CALIFORNIA ONLY: CONNECT VSV (FOR FUEL PRESSURE CONTROL) CONNECTOR AND VACUUM HOSES 6. CONNECT KNOCK SENSOR AND VSV (FOR EGR) CONNECTORS 7. CONNECT 2 ENGINE WIRE GROUND STRAPS TO INTAKE MANIFOLD 8. CONNECT VACUUM HOSES Connect the following hoses: (1) MAP sensor hose to air intake chamber (2) Brake booster vacuum hose to air intake chamber (3) Vacuum sensing hose to fuel pressure regulator. 9. w/ A/C: CONNECT A/C IDLE–UP VALVE CONNECTOR 10. INSTALL EGR VALVE AND VACUUM MODULATOR (a) Install a new gasket and the EGR valve with the union nut and 2 nuts. Union nut Torque: 59 N–m (600 kgf–cm. 43 ft–lbf) Nut Torque: 13 N–m (130 kgf–cm. 9 ft–lbf) (b) Install the EGR vacuum modulator to the clamp. EG1–200 5S–FE ENGINE – MFI/SFI SYSTEM (c) Connect the vacuum hose clamp. (d) Connect the following hoses: (1) Vacuum hose to charcoal canister (2) Vacuum hose (from EGR valves) to E port of VSV (for EGR) (3) Vacuum hose (from Q port EGR vacuum modula– tor) to G port of VSV (for EGR) (e) Connect the EGR gas temperature sensor connector. 11. CONNECT VACUUM HOSES TO VSV (FOR EVAP) (a) From P port of throttle body (b) From charcoal canister 12. CONNECT PS VACUUM HOSES 13. INSTALL THROTTLE BODY (a) Connect the following hoses to the throttle body: (1) Water bypass hose from water outlet (2) Water bypass hose from water bypass pipe (3) California: Air hose from cylinder head Except California: Air hose to air tube (b) Place a new gasket on the intake chamber, facing the protrusion downward. EG1–201 5S–FE ENGINE – MFI/SFI SYSTEM (c) Type A: Install the throttle body with the 4 bolts. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) Bolt length: A 45 mm (1.77 in.) B 55 mm (2.17 in.) (d) Type B: Install the throttle body with the 2 bolts and 2 nuts. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) (e) Connect the following hoses to the throttle body: (1) PCV hose (2) 2 vacuum hoses from EGR vacuum modulator (3) Vacuum hose from TVV (for EVAP) (f) Connect the IAC valve connector. (g) Connect the throttle position sensor connector. 14. INSTALL AIR CLEANER CAP, RESONATOR AND AIR CLEANER HOSE (a) Connect the air cleaner hose to the throttle body. (b) Install the air cleaner cap together with the resonator and air cleaner hose. (c) California only: Connect the air hose to the air cleaner hose. (d) Connect the intake air temperature sensor connector. 15. A/T: CONNECT AND ADJUST THROTTLE CABLE 16. CONNECT AND ADJUST ACCELERATOR CABLE 17. FILL WITH ENGINE COOLANT Capacity: 6.3 liters (6.7 US qts. 5.5 Imp. qts) 18. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG1–202 5S–FE ENGINE – MFI/SFI SYSTEM FUEL TANK AND LINE COMPONENTS EG1–203 5S–FE ENGINE – MFI/SFI SYSTEM PRECAUTIONS 1. Always use new gaskets when replacing the fuel tank or component parts. 2. Apply the proper torque to all parts tightened. FUEL LINES AND CONNECTIONS INSPECTION (a) Check the fuel lines for cracks, leakage and all con– nections for deformation. (b) Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. (c) Check the fuel tank for deformation, cracks, fuel leak– age and tank band looseness. (d) Check the filler neck for damage or fuel leakage. (e) Hose and tube connections are as shown in the illus– tration. If a problem is found, repair or replace the part as necessary. EG1–204 5S–FE ENGINE – MFI/SFI SYSTEM THROTTLE BODY ON–VEHICLE INPSECTION 1. INSPECT THROTTLE BODY (a) Check that the throttle linkage moves smoothly. (b) Check the vacuum at each port. • Start the engine. • Check the vacuum with your finger. Port name At idle Other than idle No vacuum Vacuum No vacuum No vacuum No vacuum Vacuum 2. INSPECT THROTTLE POSITION SENSOR (a) Apply vacuum to the throttle opener. (b) Disconnect the sensor connector. (c) Insert a thickness gauge between the throttle stop screw and stop lever. EG1–205 5S–FE ENGINE – MFI/SFI SYSTEM (d) Using an ohmmeter, measure the resistance between each terminal. Clearance between lever and stop screw Between terminals Resistance 0 mm (0 in.) VTA – E2 0.2 – 5.7 k
0.50 mm (0.020 in.) IDL – E2 2.3 k
or less 0.70 mm (0.028 in.) IDL – E2 Infinity VTA – E2 2.0 – 10.2 k
Throttle valve fully open VC – E2 2.5 – 5.9 k
(e) Reconnect the sensor connector. 3. INSPECT AND ADJUST THROTTLE OPENER A. Warm up engine Allow the engine to warm up to normal operating temperature. B. Check idle speed Idle speed: 750 ± 50 rpm C. Check and adjust throttle opener setting speed (a) Disconnect the vacuum hose from the throttle opener, and plug the hose end. (b) Maintain the engine at 2,500 rpm. (c) Release the throttle valve. (d) Check that the throttle opener is set. Throttle opener setting speed: 1,300 – 1,500 rpm (w/ Cooling fan OFF) EG1–206 5S–FE ENGINE – MFI/SFI SYSTEM (e) Adjust the throttle opener setting speed by turning the throttle opener adjusting screw. (f) Reconnect the vacuum hose to the throttle opener. COMPONENTS FOR REMOVAL AND INSTALLATION EG1–207 5S–FE ENGINE – MFI/SFI SYSTEM THROTTLE BODY REMOVAL 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. DRAIN ENGINE COOLANT 3. DISCONNECT ACCELERATOR CABLE FROM THROTTLE LINKAGE 4. A/T: DISCONNECT THROTTLE CABLE FROM THROTTLE LINKAGE 5. REMOVE AIR CLEANER CAP, RESONATOR AND AIR CLEANER HOSE (a) Disconnect the intake air temperature sensor connec– tor. (b) California only: Disconnect the air hose from the air cleaner hose. (c) Loosen the air cleaner hose clamp bolt. (d) Disconnect the 4 air cleaner cap clips. (e) Disconnect the air cleaner hose from the throttle body, and remove the air cleaner cap together with the resonator and air cleaner hose. 6. REMOVE THROTTLE BODY (a) Disconnect the throttle position sensor connector. (b) Disconnect the IAC valve connector. EG1–208 5S–FE ENGINE – MFI/SFI SYSTEM (c) Disconnect the following hoses from the throttle body. (1) PCV hose (2) 2 vacuum hoses from EGR vacuum modulator (3) Vacuum hose from TVV (for EVAP) (d) Type A: Remove the 4 bolts. (e) Type B: Remove the 2 bolts and 2 nuts. (f) Disconnect the following hoses from the throttle body, and remove the throttle body. (1) Water bypass hose from water outlet (2) Water bypass hose from water bypass pipe (3) California: Air hose from cylinder head Except California: Air hose from air tube 7. IF NECESSARY, REMOVE IAC VALVE FROM THROTTLE BODY Remove the 4 screws, IAC valve and gasket. THROTTLE BODY INSPECTION 1. CLEAN THROTTLE BODY (a) Using a soft brush and carburetor cleaner, clean the cast parts. (b) Using compressed air, clean all the passengers and apertures. NOTICE: To prevent deterioration, do not clean the throttle position sensor. EG1–209 5S–FE ENGINE – MFI/SFI SYSTEM 2. INSPECT THROTTLE VALVE (a) Apply vacuum to the throttle opener. (b) Check that there is no clearance between the throttle stop screw and throttle lever when the throttle valve is fully closed. 3. INSPECT THROTTLE POSITION SENSOR (a) Apply vacuum to the throttle opener. (b) Insert a thickness gauge between the throttle stop screw and stop lever. (c) Using an ohmmeter, measure the resistance between each terminal. Clearance between lever and stop screw 0 mm (0 in.) Between terminals VTA – E2 Resistance 0.2 – 5.7 k
0.50 mm (0.020 in.) IDL–E2 2.3 k
or less 0.70 mm (0.028 in.) IDL–E2 Infinity Throttle valve fully open VTA – E2 2.0 – 10.2 k
VC – E2 2.5 – 5.9 k
4. IF NECESSARY, ADJUST THROTTLE POSITION SENSOR (a) Loosen the 2 set screws of the sensor. (b) Apply vacuum to the throttle opener. (c) Insert a 0.60 mm (0.024 in.) thickness gauge between the throttle stop screw and stop lever. (d) Connect the test probe of an ohmmeter to the termi– nals IDL and E2 of the sensor. (e) Gradually turn the sensor clockwise until the ohmmeter deflects, and secure it with the 2 set screws. EG1–210 5S–FE ENGINE – MFI/SFI SYSTEM (f) Recheck the continuity between terminals IDL and E2. Clearance between lever and stop screw Continuity (IDL – E2) 0.50 mm (0.020 in.) Continuity 0.70 mm (0.028 in.) No continuity THROTTLE BODY INSTALLATION (See Components for Removal and Installation) 1. INSTALL IAC VALVE TO THROTTLE BODY (a) Place a new gasket on the throttle body. (b) install the IAC valve with the 4 screws. 2. INSTALL THROTTLE BODY (a) Connect the following hoses to the throttle body: (1) Water bypass hose from water outlet (2) Water bypass hose from water bypass pipe (3) California: Air hose from cylinder head Except California: Air hose from air tube (b) Place a new gasket on the intake chamber, facing the protrusion downward. EG1–211 5S–FE ENGINE – MFI/SFI SYSTEM (c) Type A: Install the throttle body with the 4 bolts. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) Bolt length: A 45 mm (1.77 in.) B 55 mm (2.17 in.) (d) Type B: Install the throttle body with the 2 bolts and 2 nuts. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) (e) Connect the following hoses to the throttle body: (1) PCV hose (2) 2 vacuum hoses from EGR vacuum modulator (3) Vacuum hose from TVV (for EVAP) (f) Connect the IAC valve connector. (g) Connect the throttle position sensor connector. 3. INSTALL AIR CLEANER CAP, RESONATOR AND AIR CLEANER HOSE (a) Connect the air cleaner hose to the throttle body. (b) Install the air cleaner cap together with the resonator and air cleaner hose. (c) California only: Connect the air hose to the air cleaner hose. (d) Connect the intake air temperature sensor connector. 4. A/T: CONNECT AND ADJUST THROTTLE CABLE 5. CONNECT AND ADJUST ACCELERATOR CABLE 6. FILL WITH ENGINE COOLANT 7. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG1–212 5S–FE ENGINE – MFI/SFI SYSTEM IDLE AIR CONTROL (IAC) VALVE ON–VEHICLE INSPECTION 1. INSPECT IAC VALVE OPERATION (a) Initial conditions: • Engine at normal operating temperature • Idle speed set correctly • Transmission in neutral position (b) Using SST, connect terminals TE1 and E1 of the data link connector 1. SST 09843–18020 (c) Maintain engine speed in the range between 900 – 1,300 rpm for 5 seconds. Check that it returns to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. (d) Remove the SST. SST 09843–18020 EG1–213 5S–FE ENGINE – MFI/SFI SYSTEM 2. INSPECT IAC VALVE RESISTANCE (a) Disconnect the IAC valve connector. (b) Using an ohmmeter, measure the resistance between terminal + B and other terminals (ISCC, ISCO). Resistance: 19.3–22–3Ω If resistance is not as specified, replace the IAC valve. (c) Reconnect the IAC valve connector. COMPONENTS FOR REMOVAL AND INSTALLATION EG1–214 5S–FE ENGINE – MFI/SFI SYSTEM IAC VALVE REMOVAL (See Components for Removal and Installation) 1. REMOVE THROTTLE BODY (See steps 1 to 6 on pages EG1–207 and 208) 2. REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket. IAC VALVE INSPECTION INSPECT IAC VALVE OPERATION (a) Connect the positive (+) lead from the battery to terminal +B and negative (–) lead to terminal ISCC, and check that the valve is closed. (b) Connect the positive (+) lead from the battery to terminal +B and negative (–) lead to terminal ISCO, and check that the valve is open. IAC VALVE INSTALLATION (See Components for Removal and Installation) 1. INSTALL IAC VALVE (a) Place a new gasket on the throttle body. EG1–215 5S–FE ENGINE – FE ENGINE – MFI/SFI SYSTEM (b) Install the IAC valve with the 4 screws. 2. INSTALL THROTTLE BODY (See steps 2 to 7 on pages EG1–210 and 211) EG1–216 5S–FE ENGINE – FE ENGINE – MFI/SFI SYSTEM EFI MAIN RELAY EFI MAIN RELAY INSPECTION 7. REMOVE EFI MAIN RELAY 2. INSPECT EFI MAIN RELAY A. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. (b) Check that there is no continuity between terminals 3 and 5. If continuity is not as specified, replace the relay. B. Inspect relay operation (a) Apply battery voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 3. REINSTALL EFI MAIN RELAY EG1–217 5S–FE ENGINE – MFI/SFI SYSTEM CIRCUIT OPENING RELAY CIRCUIT OPENING RELAY REMOVAL AND INSTALLATION EG1–218 5S–FE ENGINE – MFI/SFI SYSTEM CIRCUIT OPENING RELAY INSPECTION 1. INSPECT RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals ST and E1. (b) Check that there is continuity between terminals +B and FC. (c) Check that there is no continuity between terminals + B and FP. If continuity is not as specified, replace the relay. 2. INSPECT RELAY OPERATION (a) Apply battery voltage across terminals ST and E1. (b) Using an ohmmeter, check that there is continuity between terminals +B and FP. If operation is not as specified, replace the relay. EG1–219 5S–FE ENGINE – MFI/SFI SYSTEM ENGINE COOLANT TEMPERATURE (ECT) SENSOR ECT SENSOR INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR 3. INSPECT ECT SENSOR RESISTANCE Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph above If the resistance is not as specified, replace the sensor. 4. REINSTALL ECT SENSOR 5. FILL WITH ENGINE COOLANT EG1–220 5S–FE ENGINE – MFI/SFI SYSTEM INTAKE AIR TEMPERATURE (IAT) SENSOR IAT SENSOR INSPECTION 1. REMOVE IAT SENSOR 2. INSPECT IAT SENSOR RESISTANCE Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph above If the resistance is not as specified, replace the sensor. 3. REINSTALL IAT SENSOR EG1–221 5S–FE ENGINE – MFI/SFI SYSTEM MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR MAP SENSOR INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF MAP SENSOR (a) Disconnect the MAP sensor connector. (b) Turn the ignition switch ON. (c) Using a voltmeter measure the voltage between con– nector terminals VC and E2 of the wiring harness side. Voltage: 4.75 – 5.25 V (d) Reconnect the MAP sensor connector. EG1–222 5S–FE ENGINE – MFI/SFI SYSTEM 2. INSPECT POWER OUTPUT OF MAP SENSOR (a) Turn the ignition switch ON. (b) Disconnect the vacuum hose on the air intake cham– ber side. (c) Connect a voltmeter to terminals PIM and E2 of the ECM, and measure the output voltage under ambient atmospheric pressure. (d) Apply vacuum to the MAP sensor in 13.3 kPa (100 mmHg, 3.94 in.Hg) segments to 66.7 kPa (500 mmHg, 19.69 in.Hg). (e) Measure the voltage drop from step (c) above for each segment. Voltage drop: Applied Vacuum kPa (mmHg in.Hg) 13.3 (100 3.94 ) Voltage drop V 0.3–0.5 26.7 (200 7.87) 40.0 ( 300 111.8) 0.7–0.9 1.1 –1.3 53.5 ( 400 15.75) 1.5 – 1.7 66.7 ( 500 19.69) 1.9 – 2.1 EG1–223 5S–FE ENGINE – MFI/SFI SYSTEM VSV FOR EGR VSV INSPECTION (California) 1. REMOVE VSV (a) Disconnect the following connectors and hoses: (1) VSV for EGR (A) connector (2) VSV for fuel pressure control (B) connector (3) Vacuum hose (from EGR valve) from port E of VSV (A) (4) Vacuum hose (from port “Q” of EGR vacuum modulator) from port G of VSV (A) (5) Vacuum hose (from fuel pressure regulator) from port E of VSV (B) (6) Vacuum hose (from air intake chamber) from port G of VSV (B) (b) Remove the bolt and VSV assembly. 2. INSPECT VSV A. Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance (Cold): 33–39
If there is no continuity, replace the VSV. EG1–224 5S–FE ENGINE – MFI/SFI SYSTEM B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. C. Inspect VSV operation (a) Check that air flows from port E to port G. (b) Apply battery voltage across the terminals. (c) Check that air flows from port E to the filter. If operation is not as specified, replace the VSV. 3. REINSTALL VSV VSV INSPECTION (Except California) 1. REMOVE VSV (a) Disconnect the following connector and hoses: (1) VSV connector (2) Vacuum hose (from EGR valve) from port E of VSV (3) Vacuum hose (from port “a” of EGR vacuum modulator) from port G of VSV (b) Remove the bolt and VSV. 2. INSPECT VSV A. Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance (Cold): 33–39
If there is no continuity, replace the VSV. EG1–225 5S–FE ENGINE – MFI/SFI SYSTEM B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity,. replace the VSV. C. Inspect VSV operation (a) Check that air flows from port E to port G. (b) Apply battery voltage across the terminals. (c) Check that air flows from port E to the filter. If operation is not as specified, replace the VSV. 3. REINSTALL VSV EG1–226 5S–FE ENGINE – MFI/SFI SYSTEM VSV FOR FUEL PRESSURE CONTROL (California only) VSV INSPECTION 1. REMOVE VSV (a) Disconnect the following connectors and hoses: (1) VSV for EGR (A) connector (2) VSV for fuel pressure control (B) connector (3) Vacuum hose (from EGR valve) from port E of VSV (A) (4) Vacuum hose (from port “a” of EGR vacuum modulator) from port G of VSV (A) (5) Vacuum hose (from fuel pressure regulator) from port E of VSV (B) (6) Vacuum hose (from air intake chamber) from port G of VSV (B) (b) Remove the bolt and VSV assembly. 2. INSPECT VSV A. Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance (Cold): 33–39
If there is no continuity, replace the VSV. EG1–227 5S–FE ENGINE – MFI/SFI SYSTEM B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. C. Inspect VSV operation (a) Check that air flows from pipe E to pipe G. (b) Apply battery voltage across the terminals. (c) Check that air flows from pipe E to the filter. If operation is not as specified, replace the VSV. 3. REINSTALL VSV EG1–228 5S–FE ENGINE – MFI/SFI SYSTEM A–C IDLE–UP VALVE A/C IDLE– UP VALVE INSPECTION 1. REMOVE IDLE–UP VALVE (a) Disconnect the following connector and hoses: (1) Idle–up valve connector (2) Air hose from air intake chamber (3) Air hose from air tube (b) Remove the 2 bolts and idle–up valve together with the 2 air hoses. (c) Disconnect the 2 air hoses from the idle–up valve. 2. INSPECT IDLE–UP VALVE A. Inspect idle–up valve for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance (Cold): 30–34
If there is no continuity, replace the idle–up valve. B. Inspect idle–up valve for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the idle–up valve. EG1–229 5S–FE ENGINE – MFI/SFI SYSTEM C. Inspect idle–up valve operation (a) Check that air does not flow from port E to port F. (b) Apply battery voltage across the terminals. (c) Check that air flows from port E to port F. If operation is not as specified, replace the idle–up valve. 3. REINSTALL IDLE– UP VALVE EG1–230 5S–FE ENGINE – MFI/SFI SYSTEM EGR GAS TEMPERATURE SENSOR EGR GAS TEMPERATURE SENSOR INSPECTION 1. REMOVE EGR GAS TEMPERATURE SENSOR 2. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 64–97 k
at 50
C (122
F) 11–16 k
at 100
C (212
F) 2–4 k
at 150
C (302
F) If the resistance is not as specified, replace the sensor. 3. REINSTALL EGR GAS TEMPERATURE SENSOR EG1–231 5S–FE ENGINE – MFI/SFI SYSTEM OXYGEN SENSOR OXYGEN SENSOR INSPECTION 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. INSPECT FEEDBACK VOLTAGE Connect the positive (+) probe of a voltmeter to terminal VF1 of the data link connector 1 and nega– tive (–) probe to terminal E1. Perform the test as follows: Warm up the oxygen sensor with the engine at 2,500 rpm for approx. 90 seconds. Using SST, connect terminals TE1 and E1 of the data link connector 1. SST 09843–18020 And maintain engine speed at 2,500 rpm. Replace the ECM. Zero again After replacing 1 the oxygen sensor Check the number of times the voltmeter needle fluctuates in 10 seconds. 8 times or more Less than 8 times Warm up the oxygen sensor with the engine at 2,500 rpm for approx. 90 seconds. And maintain engine speed at 2,500 rpm. Check the number of times the voltmeter needle fluctuates in 10 seconds. Normal 8 times or more Zero Less than 8 times Disconnect terminals TE1 and E1 of the data link connector 1. And maintain engine speed at 2,500 rpm. Measure voltage between terminals VF1 and E1. More than 0 V Read and record diagnostic trouble codes. (See page EG1–297) Normal code, code Nos. 21, 25 and 26 Malfunction code(s) (Ex. code Nos. 21, 25 and 26) Repair the relevant diagnostic trouble code. CONTINUED ON PAGE EG1–232 Zero EG1–232 5S–FE ENGINE – MFI/SFI SYSTEM CONTINUED FROM PAGE EG1–231 Repair the relevant diagnostic trouble code. Malfunction code(s) (Ex. code Nos. 21, 25 and 26) Read and record diagnostic trouble codes. (See page EG1–297) Normal code, code Nos. 21, 25 and 26 Disconnect terminals TE1 and E1 of the data link connector 1. And maintain engine at 2,500 rpm. Measure voltage between terminals VF1 and E1. Disconnect the PCV hose. Measure voltage between terminals VF1 and E1. More than 0 V Repair (Over rich) Disconnect the engine coolant temp. sensor connector and connect resistor with a resistance of 4 – 8 k
or send an equivalent simulation signal. Connect terminals TE1 and E1 of the data link connector 1. Warm up the oxygen sensor with the engine at 2,500 rpm for approx. 90 seconds. And maintain engine at 2,500 rpm. Measure voltage between terminals VF1 and E1, Replace the oxygen sensor. Repair (Over Lean) EG1–233 5S–FE ENGINE – MFI/SFI SYSTEM SUB OXYGEN SENSOR SUB OXYGEN SENSOR INSPECTION INSPECT SUB OXYGEN SENSOR HINT: Inspect only when code No. 27 is displayed. (a) Cancel the diagnostic trouble code. (See page EG1–299) (b) Warm up the engine until it reaches normal operating temperature. (c) M/T: Drive for 5 minutes or more at a speed less than 80 km/h (50 mph) in 4th or 5th gear. A/T: Drive for 5 minutes or more at a speed less than 80 km/h (50 mph) in “D” position. (d) Following the conditions in step (c), fully depress on the accelerator pedal for 2 seconds or more. (e) Stop the vehicle and turn the ignition switch OFF. (f) Carry out steps (b), (c) and (d) again to test accelera– tion. If code No.27 appears again, check the sub oxygen sensor circuit. If the circuit is normal, replace the sub oxygen sensor. EG1–234 5S–FE ENGINE – MFI/SFI SYSTEM ENGINE CONTROL MODULE (ECM) ECM REMOVAL AND INSTALLATION ECM INSPECTION (See page EG1–318) EG1–235 5S–FE ENGINE – MFI/SFI SYSTEM FUEL CUT RPM FUEL CUT RPM INSPECTION 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. CONNECT TACHOMETER TO ENGINE Connect the test probe of a tachometer to terminal IG (–) of the data link connector 1. NOTICE: • NEVER allow the tachometer terminal to touch ground as it could result in damage to the igniter and/or ignition coil. • As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of yours before use. 3. INSPECT FUEL CUT RPM (a) Increase the engine speed to at least 2,500 rpm. (b) Use a sound scope to check for injector operating noise. (c) Check that when the throttle lever is released, injector operation noise stops momentarily and then resumes. HINT: Measure with the A/C OFF. Fuel return speed: 1,500 rpm 4. DISCONNECT TACHOMETER EG1–236 5S–FE ENGINE – SERVICE SPECIFICATIONS SERVICE DATA Fuel pressure regulator Fuel pressure Fuel pump Resistance Injector Resistance at no vacuum Injection volume Difference between each cylinder Fuel leakage Throttle body Throttle body fully closed angle Throttle opener setting speed Throttle Clearance between stop screw and lever position 0 mm (0 in.) sensor 0.50 mm (0.020 in.) 0.70 mm (0.028 in.) Throttle valve fully open IAC valve Resistance (+B – ISCC or ISCO) ECT sensor Resistance IAT sensor Resistance MAP sensor Power source voltage VSV for EG R Resistance VSV for Fuel pressure (California only) Resistance A/C idle –up valve Resistance EG R gas Resistance temperature sensor Fuel cut rpm Fuel return rpm MFI/SFI SYSTEM EG1–237 5S–FE ENGINE – TORQUE SPECIFICATIONS Part tightened Fuel line (Union bolt type) Fuel line (Flare nut type – use SST) Fuel tank band x Body Fuel pump x Fuel tank Fuel pressure regulator x Delivery pipe Fuel return pipe x Fuel pressure regulator Delivery pipe x Cylinder head Fuel pulsation damper x Delivery pipe Intake manifold x Cylinder head Intake manifold stay x Intake manifold Intake manifold stay x Cylinder block No.1 air intake chamber stay x Intake manifold No.1 air intake chamber stay x Cylinder head EGR pipe union nut EGR pipe x Intake manifold Throttle body x Intake manifold Fuel pump side Others MFI/SFI SYSTEM EG1–238 5S–FE ENGINE – COOLING SYSTEM COOLING SYSTEM DESCRIPTION This engine utilizes a pressurized forced circulation cooling system which includes a thermostat equipped with a bypass valve mounted on the inlet side. OPERATION The cooling system is composed of the water jacket (inside the cylinder block and cylinder head), radiator, water pump, thermostat, electric fan, hoses and other components. Engine coolant which is heated in the water jacket is pumped to the radiator, through which an electric fan blows air to cool the coolant as it passes through. Engine coolant which has been cooled is then sent back to the engine by the water pump, where it cools the engine. The water jacket is a network of channels in the shell of the cylinder block and cylinder head through which coolant passes. It is designed to provide adequate cooling of the cylinders and combustion chambers which become heated during engine operation. EG1–239 5S–FE ENGINE – COOLING SYSTEM RADIATOR The radiator performs the function of cooling the coolant which has passed through the water jacket and become hot, and it is mounted in the front of the vehicle. The radiator consists of an upper tank and lower tank, and a core which connects the two tanks. The upper tank contains the inlet for coolant from the water jacket and the filler inlet. It also has a hose attached through which excess coolant or steam can flow. The lower tank has an outlet and drain cock for the coolant. The core contains many tubes through which coolant flows from the upper tank to the lower tank as well as to cooling fins which radiate heat away from the coolant in the tubes. The air sucked through the radiator by the electric fan, as well as the wind generated by the vehicle’s travel, passes through the radiator, cooling the coolant. Models with automatic transmission include an automatic transmission fluid cooler built into the lower tank of the radiator. A fan with an electric motor is mounted behind the radiator to assist the flow of air through the radiator. The fan operates when the engine coolant temperature becomes high in order to prevent it from becoming too high. RADIATOR CAP The radiator cap is a pressure type cap which seals the radiator, resulting in pressurization of the radiator as the coolant expands. The pressurization prevents the coolant from boiling even when the engine coolant temperature exceeds 100°C (212°F). A relief valve (pressurization valve) and a vacuum valve (negative pressure valve) are built into the radiator cap. The relief valve opens and lets steam escape through the overflow pipe when the pressure generated inside the cooling system exceeds the limit (coolant temperature: 110–120°C (230–248°F), pressure; 58.8103.0 kpa (0.6–1.05 kgf/cm2, 8.5–14.9 psi). The vacuum valve opens to alleviate the vacuum which develops in the cooling system after the engine is stopped and the engine coolant temperature drops. The valve’s opening allows the coolant in the reservoir tank to return to the cooling system. RESERVOIR TANK The reservoir tank is used to catch coolant which overflows from the cooling system as a result of volumetric expansion when the coolant is heated. The coolant in the reservoir tank returns to the radiator when the coolant temperature drops, thus keeping the radiator full at all times and avoiding needless coolant loss. Check the reservoir tank level to learn if the coolant needs to be replenished. WATER PUMP The water pump is used for forced circulation of coolant through the cooling system. It is mounted on the front of the cylinder block and driven by a timing belt. THERMOSTAT The thermostat has a wax type bypass valve and is mounted in the water inlet housing. The thermostat includes a type of automatic valve operated by fluctuations in the engine coolant temperature. This valve closes when the engine coolant temperature drops, preventing the circulation of coolant through the engine and thus permitting the engine to warm up rapidly. The valve opens when the engine coolant temperature has risen, allowing the circulation of coolant. Wax inside the thermostat expands when heated and contracts when cooled. Heating the wax thus generates pressure which overpowers the force of the spring which keeps the valve closed, thus opening the valve. When the wax cools, its contraction allows the force of the spring to take effect once more, closing the valve. The thermostat in this engine operates at a temperature of 82
C (180
F). EG1–240 5S–FE ENGINE – COOLING SYSTEM PREPARATION SST (SPECIAL SERVICE TOOLS) 09228–06500 Oil Filter Wrench 09230–01010 Radiator Service Tool Set RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set EQUIPMENT Heater Engine coolant temperature switch Radiator cap tester Thermometer Engine coolant temperature switch Torque wrench COOLANT Item Engine coolant (w/ Heater) Capacity 6.3 liters (6.7 US qts, 5.5 Imp. qts) Classification Ethylene–glycol base EG1–241 5S–FE ENGINE – COOLING SYSTEM COOLANT CHECK AND REPLACEMENT 1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The engine coolant level should be between the ”LOW” and “FULL” lines. If low, check for leaks and add engine coolant up to the “FULL” line. 2. CHECK ENGINE COOLANT QUALITY There should not be any excessive deposits of rust or scales around the radiator cap or radiator filler hole, and the engine coolant should be free from oil. If excessively dirty, replace the engine coolant. 3. REPLACE ENGINE COOLANT (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove It while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) Drain the engine coolant from the radiator drain cock and engine drain plug. (Engine drain plug at the right rear of cylinder block.) (c) Close the drain cock and plug. Torque (Engine drain plug): 13 N–m (130 kgf–cm, 9 ft–lbf) (d) Slowly fill the system with coolant. Use a good brand of ethylene–glycol base coolant and mix it according to the manufacturer ’s directions. Using engine coolant which includes more than 5096 ethylene–glycol (but not more than 7096) is recommended. NOTICE: • Do not use a alcohol type coolant. • The engine coolant should be mixed with demineral– ized water or distilled water. Capacity (w/ Heater): 8.3 liters (6.7 US qts, 5.5 Imp.qts) (a) Reinstall the radiator cap. (f) Warm up the engine and check for leaks. (g) Recheck the engine coolant level and refill as neces– sary. EG1–242 5S–FE ENGINE – COOLING SYSTEM WATER PUMP COMPONENTS FOR REMOVAL AND INSTALLATION WATER PUMP REMOVAL 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the Ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is disconnected from the battery. 2. DRAIN ENGINE COOLANT (See page EG1–241) 3. REMOVE TIMING BELT (See page EG1–26) 4. REMOVE NO. 1 IDLER PULLEY AND TENSION SPRING Remove the bolt, pulley and tension spring. EG1–243 5S–FE ENGINE – COOLING SYSTEM 5. REMOVE NO.2 IDLER PULLEY Remove the bolt and pulley. 6. DISCONNECT LOWER RADIATOR HOSE FROM WATER INLET 7. REMOVE GENERATOR BELT ADJUSTING BAR Remove the bolt and adjusting bar. 8. REMOVE WATER PUMP AND WATER PUMP COVER ASSEMBLY (a) Remove the 2 nuts holding the pump to the water bypass pipe. (b) Remove the 3 bolts in the sequence shown. (c) Pull out the water pump together with the water pump cover. (d) Remove the gasket and 2 O–rings from the water pump and water bypass pipe. 9. SEPARATE WATER PUMP AND WATER PUMP COVER Remove the 3 bolts, water pump and gasket from the water pump cover. EG1–244 5S–FE ENGINE – COOLING SYSTEM 10. REMOVE WATER INLET AND THERMOSTAT FROM WATER PUMP COVER (a) Remove the 2 nuts and water inlet from the water pump. (b) Remove the thermostat. (c) Remove the gasket from the thermostat. WATER PUMP INSPECTION INSPECT WATER PUMP Turn the pulley and check that the water pump bear– ing moves smoothly and quietly. WATER PUMP INSTALLATION (See Components for Removal and Installation) 1. INSTALL THERMOSTAT AND WATER INLET TO WATER PUMP COVER (a) Install a new gasket to the thermostat. (b) Align the jiggle valve of the thermostat with the upper side of the stud bolt, and insert the thermostat in the water pump. HINT: The jiggle valve may be set within 5
of either side of the prescribed position. (c) Install the water inlet with the 2 nuts. Torque: 8.8 N–m (90 kgf–cm. 78 in.–lbf) EG1–245 5S–FE ENGINE – COOLING SYSTEM 2. ASSEMBLE WATER PUMP AND WATER PUMP COVER Install a new gasket and the water pump to the pump cover with the 3 bolts. Torque: 9.3 N–m (95 kgf–cm, 82 In.–lbf) 3. INSTALL WATER PUMP AND WATER PUMP COVER ASSEMBLY (a) Install new O–ring and gasket to water pump cover. (b) Instal a new O–ring to the water bypass pipe. (c) Apply soapy water to the O–ring on the water bypass pipe. (d) Connect the pump cover to the water bypass pipe. Do not install the nuts yet. (e) Install the water pump with the 3 bolts. Tighten the bolts in the sequence shown. Torque: 9.3 N–m (95 kgf–cm, 82 in.–lbf) EG1–246 5S–FE ENGINE – COOLING SYSTEM (f) Install the 2 nuts holding the water pump cover to the water bypass pipe. Torque: 8.8 N–m (90 kgf–cm, 78 in.–Ibf) 4. INSTALL GENERATOR BELT ADJUSTING BAR Temporarily install the adjusting bar with the bolt. 5. CONNECT LOWER RADIATOR HOSE TO WATER INLET 6. INSTALL NO.2 IDLER PULLEY (a) Install the pulley with the bolt. Torque: 42 N–m (425 kgf–cm, 31 ft–lbf) HINT: Use a bolt 35 mm (1.38 in.) in length. (b) Check that the idler pulley moves smoothly. 7. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND TENSION SPRING (a) Install the pulley with the bolt. Do not tighten the bolt yet. HINT: Use bolt 42 mm (1.65 in.) in length. (b) Install the tension spring. (c) Pry the pulley toward the left as far as it will go and tighten the bolt. (d) Check that the idler pulley moves smoothly. 8. INSTALL TIMING BELT (See page EG1–33) 9. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 10. FILL WITH ENGINE COOLANT (See page EG1–241) EG1–247 5S–FE ENGINE – COOLING SYSTEM THERMOSTAT COMPONENTS FOR REMOVAL AND INSTALLATION THERMOSTAT REMOVAL HINT: Removal of the thermostat would have an ad– verse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. 1. DRAIN ENGINE COOLANT (See page EG1–241) 2. REMOVE OIL FILTER Using SST, remove the oil filter. SST 09228–06500 3. REMOVE WATER INLET AND THERMOSTAT (a) Remove the 2 nuts and water inlet from the water pump. (b) Remove the thermostat. (c) Remove the gasket from the thermostat. EG1–248 5S–FE ENGINE – COOLING SYSTEM THERMOSTAT INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. (a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80 – 84
C (176 – 183
F) If the valve opening temperature is not as specified, replace the thermostat. (c) Check the valve lift. Valve rift: 8 mm (0.31 in.) or more at 95
C (203
F) If the valve lift is not as specified, replace the thermo– stat. (d) Check that the valve spring is tight when the thermo– stat is fully closed. If not closed, replace the thermostat. THERMOSTAT INSTALLATION (See Components for Removal and Installation) 1. PLACE THERMOSTAT IN WATER PUMP (a) Install a new gasket to the thermostat. (b) Align the jiggle valve of the thermostat with the upper side of the stud bolt, and insert the thermostat in the water pump. HINT: The jiggle valve may be set within 5
of either side of the prescribed position. 2. INSTALL WATER INLET Install the water inlet with the 2 nuts. Torque: 8.8 N–m (90 kgf–cm, 78in.–Ibf) EG1–249 5S–FE ENGINE – COOLING SYSTEM 3. INSTALL OIL FILTER (a) Clean the oil filter contact surface on the filter mounting. (b) Lubricate the filter rubber gasket with engine oil. (c) Tighten the oil filter by hand until the rubber gasket contacts the seat of the filter mounting. Then using SST, give it an additional 3/4 turn to seat the oil filter. SST 09228–06500 4. FILL WITH ENGINE OIL 5. FILL WITH ENGINE COOLANT (SEE PAGE EG1–241) 6. START ENGINE AND CHECK FOR LEAKS 7. CHECK ENGINE OIL LEVEL The oil level should be between the “L” and “F” marks on the dipstick. If low, check for leakage and add oil up to “F” mark. EG1–250 5S–FE ENGINE – COOLING SYSTEM RADIATOR RADIATOR CLEANING Using water or a steam cleaner, remove any mud or dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be care– full not to deform the fins of the radiator core. If the cleaner nozzle pressure is 2,942 – 3,432 kPa (30 – 35 kgf/cm
, 427 – 498 psi), keep a distance of at least 40 cm (15.75 in.) between the radiator core and cleaner nozzle. RADIATOR INSPECTION 1. INSPECT RADIATOR CAP NOTICE: When performing steps (a) and (b) below, keep the radiator pump tester at an angle of over 30 above the horizontal. (a) Using a radiator cap tester, slowly pump the tester and check that air is coming from the relief valve. Pump speed: 1 push/ 3 seconds or more NOTICE: Push the pump at a constant speed. If air is not coming from the relief valve, replace the radiator cap. (b) Pump the tester several times and measure the relief valve opening pressure. Pump speed: 1 at time 1 push/1 second or less 2nd time or more Any speed Standard opening pressure: 74–103 kPa (0.75–1.05 kgf/cm
, 10.7 – 14.9 psi) Minimum opening pressure: 59 kPa (0.6 kgf/cm
, 8.5 psi) If the opening pressure is less than minimum, replace the radiator cap. EG1–251 5S–FE ENGINE – COOLING SYSTEM 2. INSPECT COOLING SYSTEM FOR LEAKS (a) Fill the radiator with coolant and attach a radiator cap tester. (b) Warm up the engine. (c) Pump it to 118 kPa (1.2 kgf/cm
, 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head. COMPONENTS FOR REMOVAL AND INSTALLATION RADIATOR REMOVAL 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is discon– nected from the battery. EG1–252 5S–FE ENGINE – COOLING SYSTEM 2. DRAIN ENGINE COOLANT (See page EG1–241) 3. w/ CRUISE CONTROL SYSTEM: REMOVE CRUISE CONTROL ACTUATOR COVER 4. DISCONNECT ENGINE COOLANT TEMPERATURE SWITCH CONNECTOR FROM FAN SHROUD 5. DISCONNECT ELECTRIC COOLING FAN CONNECTORS 6. DISCONNECT RADIATOR HOSES (a) Disconnect the upper hose from the radiator side. (b) Disconnect the lower from the water inlet pipe. 7. DISCONNECT ENGINE COOLANT RESERVOIR HOSE 8. A/T: DISCONNECT OIL COOLER HOSES 9. REMOVE RADIATOR AND ELECTRIC COOLING FANS (a) Remove the 2 bolts and 2 upper supports. (b) Lift out the radiator. (c) Remove the 2 lower radiator supports. 10. REMOVE RADIATOR LOWER HOSE 11. A/T: REMOVE A/T OIL COOLER HOSES EG1–253 5S–FE ENGINE – COOLING SYSTEM 12. REMOVE ENGINE COOLANT TEMPERATURE SWITCH WIRE 13. REMOVE ELECTRIC COOLING FANS FROM RADIATOR Remove the 8 bolts and cooling fans. 14. REMOVE ENGINE COOLANT TEMPERATURE SWITCH (a) Remove the engine coolant temperature switch. (b) Remove the 0–ring. EG1–254 5S–FE ENGINE – COOLING SYSTEM COMPONENTS FOR DISASSEMBLY AND ASSEMBLY RADIATOR DISASSEMBLY 1. ASSEMBLE SST SST 09230–01010 (a) Install the claw to the overhaul handle, inserting it in the hole in part “A” as shown in the diagram. (b) While gripping the handle, adjust the stopper bolt so that dimension “B” shown in the diagram is 0.2–0.5 mm (0.008–0.020 in.). NOTICE: If this adjustment is not performed, the claw may be damaged. EG1–255 5S–FE ENGINE – COOLING SYSTEM 2. UNCAULK LOCK PLATES Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST 09230–01010 3. REMOVE TANKS AND O–RINGS (a) Lightly tap the radiator hose inlet (or outlet) with a soft–faced hammer and remove the tank. (b) Remove the 0–ring. 4. A/T: REMOVE OIL COOLER FROM LOWER TANK (a) Remove the pipes. HINT: Make a note of the direction to face the pipes. (b) Remove the nuts and plate washers. (c) Remove the oil cooler and 0–rings. RADIATOR ASSEMBLY (See Components for Disassembly and Assembly) 1. A/T: INSTALL OIL COOLER TO LOWER TANK (a) Clean the 0–ring contact surface of the lower tank and oil cooler. (b) Install new 0–rings (1) to the oil cooler (2). (c) Install the oil cooler with the 0–rings to the lower tank (3). (d) Install the plate washers (4) and nuts (5). Torque the nuts. Torque: 8.3 N–m (85 kgf–cm, 74 in.–lbf) (e) Install the pipes (6). Torque: 22 N–m (220 kgf–cm, 16 ft–lbf) HINT: Face the pipes in the same direction as before disassembly. EG1–256 5S–FE ENGINE – COOLING SYSTEM 2. INSPECT LOCK PLATE Inspect the lock plate for damage. HINT: • If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. • Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the bottom of the lock plate groove is damaged or dented. There– fore, repair or replace if necessary. 3. INSTALL NEW O–RINGS AND TANKS (a) After checking that there are no foreign objects in the lock plate groove, install the new O–ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. (b) Install the tank without damaging the 0–ring. (c) Tap the lock plate with a soft–faced hammer so that there is no gap between it and the tank. 4. ASSEMBLE SST SST 09230–01010 (a) Install the punch assembly to the overhaul handle, inserting it in the hole in part “A” as shown in the illustration. (b) While gripping the handle, adjust the stopper bolt so that dimension “B” shown in the diagram is 7.7 mm (0.03 in.) 5. CAULK LOCK PLATE (a) Lightly press SST against the lock plate in the order shown in the illustration. EG1–257 5S–FE ENGINE – COOLING SYSTEM After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper plate. SST 09230 – 01010 HINT: • Do not stake the areas protruding around the pipes, brackets or tank ribs. • The points shown in the illustration and oil cooler near here (A/T) cannot be staked with the SST. Use a plier or like object and be careful not to damage the core plates. (b) Check the lock plate height (H) after completing the caulking. Plate height: 7.75–8.25 mm (0–3051–0.3248 in.) If not within the specified height, adjust the stopper bolt of the handle again and perform the caulking again. 6. INSPECT FOR WATER LEAKS (a) Tighten the drain cock. (b) Plug the inlet and outlet pipes of the radiator with SST. SST 09230 – 01010 (c) Using a radiator cap tester, apply pressure to the radiator. Test pressure: 177 kPa (1.8 kgf/cm
, 26 psi) EG1–258 5S–FE ENGINE – COOLING SYSTEM (d) Inspect for water leaks. HINT: On radiators with resin tanks, there is a clear– ance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before performing the water leak test, first switch the radiator around in the water until all air bubbles disappear. 7. PAINT LOCK PLATES HINT: If the water leak test checks out okay, allow the radiator to completely dry and then paint the lock plates. RADIATOR INSTALLATION (See Components for Removal and installation) 1. INSTALL ENGINE COOLANT TEMPERATURE SWITCH (a) Install a new O–ring to the engine coolant tempera– ture switch. (b) Install the engine coolant temperature switch. 2. INSTALL ELECTRIC COOLING FANS TO RADIATOR Install the cooling fans with the 8 bolts. 3. INSTALL ENGINE COOLANT TEMPERATURE SWITCH WIRE EG1–259 5S–FE ENGINE – COOLING SYSTEM 4. A/T: INSTALL A/T OIL COOLER HOSES 5. INSTALL RADIATOR LOWER HOSE 6. INSTALL RADIATOR AND ELECTRIC COOLING FANS (a) Place the 2 lower radiator supports in position on the body. (b) Place the radiator in position, and install the 2 upper supports with the 2 bolts. HINT: After installation, check that the rubber cushion (A) of the support is not depressed. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) 7. A/T: CONNECT OIL COOLER HOSES 8. CONNECT ENGINE COOLANT RESERVOIR HOSE 9. CONNECT RADIATOR HOSES EG1–260 5S–FE ENGINE – COOLING SYSTEM 10. CONNECT ELECTRIC COOLING FAN CONNECTORS 11. CONNECT ENGINE COOLANT TEMPERATURE SWITCH CONNECTOR TO FAN SHROUD 12. w/ CRUISE CONTROL SYSTEM: INSTALL CRUISE CONTROL ACTUATOR COVER 13. FILL WITH ENGINE COOLANT (See page EG1–241) 14. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 15. START ENGINE AND CHECK FOR LEAKS 16. A/T: CHECK AUTOMATIC TRANSMISSION (A/T) FLUID LEVEL NOTICE: Do not overfill. EG1–261 5S–FE ENGINE – COOLING SYSTEM ELECTRIC COOLING FAN PART LOCATION SYSTEM CIRCUIT EG1–262 5S–FE ENGINE – COOLING SYSTEM ON–VEHICLE INSPECTION Low Temperature (Below 83
C (181
F)) 1. TURN IGNITION SWITCH “ON” Check that the cooling fan stops. If not, check the cooling fan relay and engine coolant temperature switch, and check for a separated con– nector or severed wire between the cooling fan relay and engine coolant temperature switch. 2. DISCONNECT ENGINE COOLANT TEMPERATURE SWITCH CONNECTOR Check that the cooling fan rotates. If not, check the cooling fan relay, cooling fan, engine main relay and fuse, and check for a short circuit between the cooling fan relay and engine coolant temperature switch. 3. CONNECT ENGINE COOLANT TEMPERATURE SWITCH CONNECTOR High Temperature (Above 93
C (199
F)) 4. START ENGINE (a) Raise engine coolant temperature to above 93
C (199
F). (b) Check that the cooling fan rotates. If not, replace the engine coolant temperature switch. 9=4 –01 ELECTRIC COOLING FAN COMPONENTS INSPECTION 1. INSPECT ENGINE COOLANT TEMPERATURE SWITCH (a) Using an ohmmeter, check that there is no continuity between the terminals when the engine coolant tem– perature is above 93
C (199
F). (b) Using an ohmmeter, check that there is continuity between the terminals when the engine coolant tem– perature is below 83
C (181
F). If continuity is not as specified, replace the switch. EG1–263 5S–FE ENGINE – COOLING SYSTEM 2. INSPECT COOLING FAN RELAY (”FAN’) A. Remove cooling fan relay B. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. (b) Check that there is continuity between terminals 3 and 4. If continuity is not as specified, replace the relay. C. Inspect relay operation (a) Apply battery voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is no continuity between terminals 3 and 4. If operation is not as specified, replace the relay. D. Reinstall cooling fan relay 3. INSPECT ENGINE MAIN RELAY (“ENG MAIN”) A. Remove engine main relay B. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals 3 and 5. (b) Check that there is continuity between terminals 2 and 4. (c) Check that there is no continuity between terminals 1 and 2. If continuity is not as specified, replace the relay. EG1–264 5S–FE ENGINE – COOLING SYSTEM C. Inspect relay operation (a) Apply battery voltage across terminals 3 and 5. (b) Using an ohmmeter, check that there is no continuity between terminals 2 and 4. (c) Check that there is continuity between terminals 1 and 2. If operation is not as specified, replace the relay. D. Reinstall engine main relay 4. INSPECT COOLING FAN (a) Connect battery and ammeter to the cooling fan con– nector. (b) Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage: 5.8 – 7.4 A COMPONENTS FOR REMOVAL AND INSTALLATION EG1–265 5S–FE ENGINE – COOLING SYSTEM ELECTRIC COOLING FAN REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. DRAIN ENGINE COOLANT (See page EG1–241) 3. w/ CRUISE CONTROL SYSTEM: REMOVE CRUISE CONTROL ACTUATOR COVER 4. DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR 5. REMOVE ELECTRIC COOLING FAN (a) Disconnect the engine coolant temperature switch connector from the radiator. (b) Disconnect the engine coolant temperature switch and electric cooling fan connectors from the fan shroud. (c) Remove the 4 bolts and cooling fan. COMPONENTS FOR DISASSEMBLY AND ASSEMBLY EG1–266 5S–FE ENGINE – COOLING SYSTEM ELECTRIC COOLING FAN DISASSEMBLY (See Components for Disassembly and Assembly) 1. REMOVE FAN Remove the nut and fan. 2. REMOVE FAN MOTOR Remove the screws and fan motor. ELECTRIC COOLING FAN ASSEMBLY (See Components for Disassembly and Assembly) 1. INSTALL FAN MOTOR 2. INSTALL FAN ELECTRIC COOLING FAN INSTALLATION (See Components for Removal and Installation) 1. INSTALL ELECTRIC COOLING FAN (a) Install the cooling fan with the 4 bolts. (b) Connect the engine coolant temperature switch and electric cooling fan connectors to the fan shroud. (c) Connect the engine coolant temperature switch connector to the radiator. 2. CONNECT UPPER RADIATOR HOSE TO RADIATOR 3. w/ CRUISE CONTROL SYSTEM: INSTALL CRUISE CONTROL ACTUATOR COVER 4. FILL WITH ENGINE COOLANT (See page EG1–241) 5. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 6. START ENGINE AND CHECK FOR LEAKS EG1–267 5S–FE ENGINE SERVICE SPECIFICATIONS SERVICE DATA Thermostat Valve opening temperature Radiator cap Relief valve opening pressure Radiator Plate height Electric Rotating amperage Valve lift cooling fan TORQUE SPECIFICATIONS Part tightened Cylinder block x Drain plug Water inlet x Water pump cover Water pump x Water pump cover Water pump x Cylinder block Water bypass pipe x Water pump cover No.2 idler pulley x Cylinder block Water inlet x Water pump Radiator oil cooler x Radiator lower tank Radiator oil cooler pipe Radiator support bolt – COOLING SYSTEM EG1–268 5S–FE ENGINE – LUBRICATION SYSTEM LUBRICATION SYSTEM DESCRIPTION A fully pressurized, fully filtered lubrication system has been adopted for this engine. OPERATION EG1–269 5S–FE ENGINE – LUBRICATION SYSTEM A pressure feeding lubrication system has been adopted to supply oil to the moving parts of this engine. The lubrication system consists of an oil pan, oil pump, oil filter and other external parts which supply oil to the moving parts in the engine block. The oil circuit is shown in the illustration at the top of the previous page. Oil from the oil pan is pumped up by the oil pump. After it passes through the oil filter, it is through the various oil holes in the crankshaft and cylinder block. After passing through the cylinder block and performing its lubricating function, the oil is returned by gravity to the oil pan. A dipstick on the center left side of the cylinder block is provided to check the oil level. OIL PUMP The oil pump pumps up oil from the oil pan and feeds it under pressure to the various parts of the engine. An oil strainer is mounted in front of the inlet to the oil pump to remove impurities. The oil pump itself is a trochoid type pump, inside of which is a drive rotor and a driven rotor. When the drive rotor rotates, the driven rotor rotates in the same direction, and since the axis of the drive rotor shaft is different from the center of the driven rotor, the space between the two rotors changes as they rotate. Oil is drawn in when the space widens and is discharged when the space becomes narrow. OIL PRESSURE REGULATOR (RELIEF VALVE) At high engine speeds, the engine oil supplied by the oil pump exceeds the capacity of the engine to utilize it. For that reason, the oil pressure regulator works to prevent an oversupply of oil. During normal oil supply, a coil spring and valve keep the bypass closed, but when too much oil is being fed, the pressure becomes extremely high, overpowering the force of the spring and opening the valves. This allows the excess oil to flow through the valve and return to the oil pan. OIL FILTER The oil filter is a full flow type filter with a relief valve built into the paper filter element. Particles of metal from wear, airborne dirt, carbon and other impurities can get into the oil during use and could cause accelerated wear or seizing if allowed to circulate through the engine. The oil filter, integrated into the oil line, removes these impurities as the oil passes through it. The filter is mounted outside the engine to simplify replacement of the filter element. A relief valve is also included ahead of the filter element to relieve the high oil pressure in case the filter element becomes clogged with impurities. The relief valve opens when the oil pressure overpowers the force of the spring. Oil passing through the relief valve bypasses the oil filter and flows directly into the main oil hole in the engine. EG1–270 5S–FE ENGINE – LUBRICATION SYSTEM PREPARATION SST (SPECIAL SERVICE TOOLS) 09032–00100 Oil Pan Seat Cutter 09226–10010 Crankshaft Front & Rear Bearing Replacer Crankshaft front oil seal 09228–06500 Oil Filter wrench 09616–30011 Steering Worm Bearing Adjusting Screw Wrench Oil pump pulley 09620–30010 Steering Gear Box Replacer Set (09627–30010) Steering Sector Shaft Bushing Replacer Oil pump oil seal (09631–00020) Handle Oil pump oil seal RECOMMENDED TOOLS 09090–04000 Engine Sling Device For suspending engine 09200–00010 Engine Adjust Kit 09905–00013 Snap Ring Pliers EQUIPMENT Oil pressure gauge Precision straight edge Torque wrench Oil pump EG1–271 5S–FE ENGINE – LUBRICATION SYSTEM LUBRICANT Item Engine oil (M/T) Dry fill Capacity Classification API grade SG or SH, Energy–Conserving ΙΙ 4.2 liters (4.4 US qts, 3.7 Imp. qts) Drain and refill mutigrade engine oil or ILSAC multigrade engine oil and recommended viscosity oil w/ Oil filter change 3.6 liters (3.8 US qts, 3.2 Imp. qts) w/o Oil filter change 3.4 liters (3.6 US qts, 3.0 Imp. qts) Engine oil (A/T) Dry fill 4.3 liters (4.5 US qts, 3.8 imp. qts) Drain and refill w/ Oil filter change 3.6 liters (3.8 US qts, 3.2 Imp. qts) w/o Oil filter change 3.4 liters (3.6 US qts, 3.0 Imp. qts) SSM (SPECIAL SERVICE MATERIALS) 08826–00080 Seal packing or equivalent Oil pan 08833–00080 Adhesive 1344, THREE BOND 1344, LOCTITE 242 or equivalent Oil pressure switch EG1–272 5S–FE ENGINE – LUBRICATION SYSTEM OIL PRESSURE CHECK 1. CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, dis– coloring or thinning. If the quality is visibly poor, replace the oil. Oil grade: API grade SG or SH, Energy Conserving II multi– grade engine oil or ILSAC multigrade engine oil. Recommended viscosity is as shown in the illustra– tion. 2. CHECK ENGINE OIL LEVEL The oil level should be between the “L” and “F” marks on the dipstick. If low, check for leakage and add oil up to “F” mark. NOTICE: • When inserting the oil dipstick, insert the curved tip of the dipstick facing the same direction as the curve of the guide. • If the dipstick gets caught while inserting it, do not force it in. Reconfirm the direction of the dipstick. 3. REMOVE OIL PRESSURE SWITCH, AND INSTALL OIL PRESSURE GAUGE 4. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 5. CHECK OIL PRESSURE Oil pressure: At idle 29 kPa (0.3 kgf/cm
, 4.3 psi) or more At 3,000 rpm 245 – 490 kPa (2.5 – 5.0 kg f/cm
, 36 – 71 psi) EG1–273 5S–FE ENGINE – LUBRICATION SYSTEM 6. REMOVE OIL PRESSURE GAUGE AND REINSTALL OIL PRESSURE SWITCH (a) Remove the oil pressure gauge. (b) Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No.08833 – 00080, THREE BOND 1344, LOCTITE 242 or equivalent (c) Reinstall the oil pressure switch. 7. START ENGINE AND CHECK FOR LEAKS EG1–274 5S–FE ENGINE – LUBRICATION SYSTEM OIL AND FILTER REPLACEMENT CAUTION: • Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addi– tion, used engine oil contains potentially harmful contaminants which may cause skin cancer. • Care should be taken, therefore, when changing engine, oil to minimize the frequency and length of time your skin is exposed to used engine oil. Protec– tive clothing and gloves that cannot be penetrated by oil should be worn. The skin should be thorought– hly washed with soap and water, or use water–less hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. • In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal sites. 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil drain plug, and drain the oil into a container. 2. REPLACE OIL FILTER (a) Using SST, remove the oil filter. SST 09228–06500 (b) Check and clean the oil filter installation surface. EG1–275 5S–FE ENGINE – LUBRICATION SYSTEM (c) Apply clean engine oil to the gasket of a new oil filter. (d) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. (e) Using SST, tighten it an additional 3/4 turn. SST 09228–06500 3. FILL WITH ENGINE OIL (a) Clean and install the oil drain plug with a new gasket. Torque: 39 N–m (400 kgf–cm, 29 ft–lbf) (b) Fill with new engine oil. Oil grade: (See step 1 on page EG1–272) Capacity (M/T): Drain and refill w/ Oil filter change 3.6 liters (3.8 US qts, 3.2 Imp. qts) w/o Oil filter change 3.4 liters (3.6 US qts, 3.0 Imp. qts) Dry fill 4.2 liters (4.4 US qts, 3.7 Imp. qts) Capacity (A/T): Drain and refill w/ Oil filter change 3.6 liters (3.8 US qts, 3.2 Imp. qts) w/o Oil filter change 3.4 liters (3.6 US qts, 3.0 Imp. qts) Dry fill 4.3 liters (4.5 US qts, 3.8 Imp. qts) (c) Reinstall the oil filler cap. 4. START ENGINE AND CHECK FOR LEAKS 5. RECHECK ENGINE OIL LEVEL (See page EG1–272) EG1–276 5S–FE ENGINE – LUBRICATION SYSTEM OIL PUMP COMPONENTS FOR REMOVAL AND INSTALLATION OIL PUMP REMOVAL HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned. 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE HOOD 3. DRAIN ENGINE OIL (See page EG1–274) EG1–277 5S–FE ENGINE – LUBRICATION SYSTEM 4. REMOVE FRONT EXHAUST PIPE (a) Loosen the 2 bolts, and disconnect the bracket. (b) Remove the 2 bolts and nuts holding the front exhaust pipe to the center exhaust pipe. (c) Using a 14 mm deep socket wrench, remove the 3 nuts holding the front exhaust pipe to the WU–TWC. (d) Remove the front exhaust pipe and gaskets. 5. REMOVE STIFFENER PLATE Remove the 3 bolts and stiffener plate. 6. REMOVE OIL PAN (a) Remove the dipstick. (b) Remove the 17 bolts and 2 nuts. (c) Insert the blade of SST between the cylinder block and oil pan, and cut off applied sealer and remove the oil pan. SST 09032 – 00100 NOTICE: • Do not use SST for the oil pump body side and rear oil seal retainer. • Be careful not to damage the oil pan flange. 7. REMOVE OIL STRAINER Remove the bolt, nuts, oil strainer and gasket. EG1–278 5S–FE ENGINE – LUBRICATION SYSTEM 8. SUSPEND ENGINE WITH ENGINE SLING DEVICE 9. REMOVE TIMING BELT (See page EG1–26) 10. REMOVE NO.2 IDLER PULLEY Remove the bolt and pulley. 11. REMOVE CRANKSHAFT TIMING PULLEY If the pulley cannot be removed by hand, use 2 screw– drivers. HINT: Position shop rags as shown to prevent damage. 12. REMOVE OIL PUMP PULLEY Using SST, remove the nut and pulley. SST 09616 – 30011 13. REMOVE OIL PUMP (a) Remove the 12 bolts. EG1–279 5S–FE ENGINE – LUBRICATION SYSTEM (b) Using a plastic–faced hammer, remove the oil pump by carefully tapping the oil pump body. (c) Remove the gasket. COMPONENTS FOR DISASSEMBLY AND ASSEMBLY OIL PUMP DISASSEMBLY 1. REMOVE RELIEF VALVE (a) Using snap ring pliers, remove the snap ring. (b) Remove the retainer, spring and relief valve. EG1–280 5S–FE ENGINE – LUBRICATION SYSTEM 2. REMOVE DRIVE AND DRIVEN ROTORS Remove the 2 bolts, pump body cover, O–ring, the drive and driven rotors. OIL PUMP INSPECTION 1. INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it doesn’t, replace the relief valve. If necessary, replace the oil pump assembly. 2. INSPECT DRIVE AND DRIVEN ROTORS A. Inspect rotor body clearance Using a thickness gauge, measure the clearance be– tween the driven rotor and body. Standard body clearance: 0.10 – 0.16 mm (0.0039 – 0.0063 in.) Maximum body clearance: 0.20 mm (0.0079 in.) If the body clearance is greater than maximum, re– place the rotors as a set. If necessary, replace the oil pump assembly. B. Inspect rotor tip clearance Using a thickness gauge, measure the clearance be– tween the drive and driven rotor tips. Standard tip clearance: 0.04 – 0.16 mm (0.0016 – 0.0063 in.) Maximum tip clearance: 0.20 mm (0.0079 in.) If the tip clearance is greater than maximum, replace the rotors as a set. EG1–281 5S–FE ENGINE – LUBRICATION SYSTEM OIL PUMP OIL SEAL REPLACEMENT 1. REMOVE OIL SEAL Using a screwdriver, pry out the oil seal. 2. INSTALL OIL SEAL (a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump cover edge. SST 09620–30010 (09627–30010, 09631–00020) (b) Apply MP grease to the oil seal lip. CRANKSHAFT FRONT OIL SEAL REPLACEMENT HINT: There are 2 methods (A and B) to replace the oil seal which are as follows: REPLACE CRANKSHAFT FRONT OIL SEAL A. If oil pump is removed from cylinder block: (a) Using screwdriver and hammer, tap out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump case edge. SST 09226 –10010 (c) Apply MP grease to the oil seal lip. EG1–282 5S–FE ENGINE – LUBRICATION SYSTEM B. If oil pump is installed to the cylinder block: (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. (c) Apply MP grease to a new oil seal lip. (d) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump case edge. SST 09226 –10010 OIL PUMP ASSEMBLY (See Components for Disassembly and Assembly) 1. INSTALL DRIVE AND DRIVEN ROTORS (a) Place the drive and driven rotors into pump body with the marks facing the pump body cover side. (b) Install the pump body cover with the 2 bolts. Torque: 8.8 N–m (90 kgf–cm. 78 in.–lbf) 2. INSTALL RELIEF VALVE (a) Insert the relief valve, spring and retainer into the pump body hole. (b) Using snap ring pliers, install the snap ring. EG1–283 5S–FE ENGINE – LUBRICATION SYSTEM OIL PUMP INSTALLATION (See Components for Removal and Installation) 1. INSTALL OIL PUMP Install a new gasket and the oil pump with the 12 bolts. Torque: 9.3 N–m (95 kgf–cm, 82 in.–lbf) HINT: Long bolts are indicated in the illustration. Bolt length: Long bolt 35 mm (1.38 in.) Others 25 mm (0.98 in.) 2. INSTALL OIL PUMP PULLEY (a) Align the cutouts of the pulley and shaft, and slide on the pulley. (b) Using SST, install the nut. SST 09616–30011 Torque: 28 N–m (290 kgf–cm, 21 ft–lbf) 3. INSTALL CRANKSHAFT TIMING PULLEY (a) Align the timing pulley set key with the key groove of the pulley. (b) Slide on the timing pulley, facing the flange side inward. EG1–284 5S–FE ENGINE – LUBRICATION SYSTEM 4. INSTALL NO.2 IDLER PULLEY (a) Install the pulley with the bolt. Torque: 42 N–m (425 kgf–cm, 31 ft–lbf) HINT: Use a bolt 35 mm (1.38 in.) in length. (b) Check that the idler pulley moves smoothly. 5. INSTALL TIMING BELT (See page EG1–33) 6. REMOVE ENGINE SLING DEVICE 7. INSTALL OIL STRAINER Install a new gasket and the oil strainer with bolt and nuts. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) 8. INSTALL OIL PAN (a) Remove any old packing (FIPG) material and be care– ful not to drop any oil on the contact surfaces of the oil pan and cylinder block. • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. • Thoroughly clean all components to remove all the loose material. • Using a non–residue solvent, clean both sealing surfaces. NOTICE: Do not use a solvent which will affect the paint– ed surfaces. (b) Apply seal packing to the oil pan as shown in the illustration. Seal packing: Part No.08826 – 00080 or equivalent • Install a nozzle that has been cut to a 3–5 mm (0.12–0.20 in.) opening. • Parts must be assembled within 5 minutes of application. Otherwise the material must be re– moved and reapplied. • Immediately remove nozzle from the tube and reinstall cap. EG1–285 5S–FE ENGINE – LUBRICATION SYSTEM (c) Install the oil pan with 17 bolts and 4 nuts. Torque: 5.4 N–m (55 kgf–cm, 48 in.–lbf) (d) Install the dipstick. 9. INSTALL STIFFENER PLATE Install the stiffener plate with the 3 bolts. Torque: 37 N–m (380 kgf–cm, 27 ft–Ibf) 10. INSTALL FRONT EXHAUST PIPE (a) Place 2 new gaskets on the front and rear of the front exhaust pipe. (b) Temporarily install the 2 bolts and 2 new nuts holding front exhaust pipe to the center exhaust pipe. (c) Using a 14 mm deep socket wrench, install the 3 new nuts holding the front exhaust pipe to the WU–TWC. Torque: 62 N–m (630 kgf–cm, 46 ft–lbf) (d) Tighten the 2 bolts and 2 nuts holding front exhaust pipe to the center exhaust pipe. Torque: 56 N–m (570 kgf–cm, 41 ft–lbf) (e) Install the bracket with the 2 bolts. 11. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 12. FILL WITH ENGINE OIL (See page EG1–275) 13. START ENGINE AND CHECK FOR LEAKS 14. RECHECK ENGINE OIL LEVEL 15. INSTALL HOOD EG1–286 5S–FE ENGINE – LUBRICATION SYSTEM OIL COOLER COMPONENTS FOR REMOVAL AND INSTALLATION OIL COOLER REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE OIL FILTER Using SST, remove the oil filter. SST 09228–06500 3. DISCONNECT WATER BYPASS HOSES FROM OIL COOLER Disconnect the 2 water bypass hoses. EG1–287 5S–FE ENGINE – LUBRICATION SYSTEM 4. REMOVE OIL COOLER (a) Remove the relief valve and plate washer. (b) Remove the nut and oil cooler. (c) Remove the O–ring and gasket from the oil cooler. OIL COOLER INSPECTION 1. INSPECT RELIEF VALVE Push the valve with a wooden stick to check if it is stuck. If stuck, replace the relief valve. 2. INSPECT OIL COOLER Check the oil cooler for damage or clogging. If necessary, replace the oil cooler. OIL COOLER INSTALLATION (See Components for Removal and Installation) 1. INSTALL OIL COOLER (a) Install new O–ring and gasket to the oil cooler. (b) Apply a light coat of engine oil on the threads and under the head of the relief valve. (c) Temporarily install the oil cooler with the nut. (d) Install the plate washer and relief valve. Torque: 78 N–m (800 kgf–cm, 58 ft–lbf) (e) Tighten the nut. Torque: 7.8 N–m (80 kgf–cm, 69 In.–lbf) EG1–288 5S–FE ENGINE – LUBRICATION SYSTEM 2. CONNECT WATER BYPASS HOSES Connect the 2 water bypass hoses. 3. INSTALL OIL FILTER (a) Clean the oil filter contact surface on the filter mounting. (b) Lubricate the filter rubber gasket with engine oil. (c) Tighten the oil filter by hand until the rubber gasket contacts the seat of the filler mounting. Then using SST, give it an additional 3/4 turn to seat the oil filter. SST 09228–06500 4. FILL WITH ENGINE COOLANT (See page EG1–241) 5. START ENGINE AND CHECK FOR LEAKS 6. CHECK ENGINE OIL LEVEL EG1–289 5S–FE ENGINE SERVICE SPECIFICATIONS SERVICE DATA Oil pressure Oil pump Body clearance Tip clearance TORQUE SPECIFICATIONS Part tightened Oil pan x Drain plug Oil pump body cover x Oil pump body Oil pump x Cylinder block Oil pump pulley x Oil pump drive shaft No.2 idler pulley x Cylinder block Oil strainer x Cylinder block Oil strainer x Oil pump Oil pan x Cylinder block Oil pan x Oil pump Stiffener plate x Cylinder block Stiffener plate x Transaxle case Front exhaust pipe x WU–TWC Front exhaust pipe x Center exhaust pipe Oil cooler x Cylinder block (Relief valve) Oil cooler x Cylinder block (Nut) – LUBRICATION SYSTEM 5S-FE ENGINE – -Memo EG1–291 5S–FE ENGINE – 5S–FE ENGINE TROUBLESHOOTING EG1–292 5S–FE ENGINE – HOW TO PROCEED WITH TROUBLESHOOTING HOW TO PROCEED WITH TROUBLESHOOTING The Engine Control System broadly consists of the sensors, Engine Control Module (ECM) and actuators. The ECM receives signals from various sensors, judges the operating conditions and determines the optimum injection duration, timing, ignition timing and idle speed. In general, the Engine Control System is considered to be a very intricate system to troubleshoot. But, the fact is that if you proceed to inspect the circuit one by one following the procedures directed in this manual, troubleshooting of this system is not complex. This section explains the most ideal method of troubleshooting and tells how to carry out the necessary repairs. 1. CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in as much details as possible about the problem. 2. CHECK AND CLEAR DIAGNOSTIC TROUBLE CODE (PRECHECK) Before confirming the problem symptom, first check the diagnostic trouble code and make a note of any malfunction code which is output, then clear the code. HINT: Output of the malfunction code indicates that there is a malfunction in the circuit indicated. However, it does not indicate whether the malfunction is still occurring or occurred in the past and returned to normal. In order to determine this, the problem sym toms should be confirmed in step 4 first and the diagnostic trouble code be rechecked in step [6]. Accordingly, if troubleshooting is begun based on the malfunction code only in diagnostic trouble code check in step [2], it could result in a misdiagnosis, leading to troubleshooting of circuits which are normal and making it more difficult to locate the cause of the problem. 3. SETTING THE TEST MODE DIAGNOSIS, [4] PROBLEM SYMPTOM CONFIRMATION, [5] SYMPTOM SIMULATION In order to find out the trouble more quickly, set the diagnosis check in test mode and with higher sensing ability of the ECM, confirm the problem symptoms. If the trouble does not reappear, use the symptom simulation method to make sure the trouble is reproduced. 6. DIAGNOSTIC TROUBLE CODE CHECK IN TEST MODE Check the diagnostic trouble code in test mode. If the malfunction code is output, proceed to step. If the normal code is output, proceed to step [7]. 7. BASIC INSPECTION Carry out basic inspection such as the spark check and fuel pressure check, etc. 8. DIAGNOSTIC TROUBLE CODE CHART If the malfunction code is displayed, proceed to inspect the circuit indicated by the chart for each code. 9. MATRIX CHART OF PROBLEM SYMPTOMS If the normal code is displayed in the diagnosis in test mode, perform troubleshooting according to the inspection order in the Matrix Chart of Problem Symptoms. 10. PARTS INSPECTION When the Matrix Chart of Problem Symptoms instructs to check the parts, proceed to parts inspection section included in this manual. 11. CIRCUIT INSPECTION Determine if the malfunction is the sensor, actuator, wire harness, connector or the ECM. EG1–293 5S–FE ENGINE – HOW TO PROCEED WITH TROUBLESHOOTING CHECK FOR MOMENTARY INTERRUPTION By performing the check for momentary interruption, the place where momentary interruptions or momentary shorts are occurring due to poor contacts can be isolated. ADJUSTMENT, REPAIR After the cause of the problem is located, perform adjustment or repairs by following the inspection and replacement procedures in this manual. CONFIRMATION TEST After completing adjustment or repairs, confirm not only that the malfunction is eliminated, but also conduct a test drive, etc., to make sure the entire Engine Control System is operating normally. EG1–294 5S–FE ENGINE – HOW TO PROCEED WITH TROUBLESHOOTING Titles inside are titles of pages in this manual, with the page number indicated in the bottom portion. See the indicated pages for detailed explanations Vehicle Brought to Workshop Customer Problem Analysis P. EG1–295 Check and clear Diagnostic Trouble Code (Precheck.) P. EG1–297, 299 Setting the Test Mode Diagnosis P. EG1–298 Problem Symptom Confirmation Malfunction does not occur. Malfunction occurs: Symptom Simulation P. IN–24 Diagnostic Trouble Code Check P. EG1–298 Malfunction code Normal code Basic Inspection Diagnostic Trouble Code Chart P. EG1–300 p. EG1–310 Matrix Chart of Problem Symptoms P. EG1–327 Circuit Inspection P. EG1–336 Check for Momentary Interruption Parts Inspection P. EG1–309 Identification of Problem Adjustment, Repair Confirmation Test End Step : Diagnostic steps per– mitting the use of the TOYOTA hand–held tester or TOYOTA break–out–box. EG1–295 5S–FE ENGINE – CUSTOMER PROBLEM ANALYSIS CHECK SHEET CUSTOMER PROBLEM ANALYSIS CHECK SHEET EG1–296 5S–FE ENGINE – DIAGNOSIS SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The ECM contains a built–in self–diagnosis system by which troubles with the engine signal network are detected and a Malfunction indicator lamp on the instrument panel lights up. By analyzing various signals as shown in the later table (See page EG1–300) the Engine Control Module (ECM) detects system malfunctions relating to the sensors or actuators. In the normal mode, the self–diagnosis system monitors 14 items, indicated by code No. as shown in EG1–300. A malfunction indicator lamp informs the driver that a malfunction has been detected. The light goes off automatically when the malfunction has been repaired. But the diagnostic trouble code(s) remains stored in the ECM memory (except for code Nos. 16). The ECM stores the code(s) until it is cleared by removing the EFI fuse with the ignition switch off. The diagnostic trouble code can be read by the number of blinks of the malfunction indicator lamp when TE1 and E1 terminals on the data link connector 1 or 2 are connected. When 2 or more codes are indicated, the lowest number (code) will appear first. In the test mode, 9 items, indicated by code No. as shown in EG1–300 are monitored. If a malfunction is detected in any one of the systems indicated by code Nos. 13, 22, 24, 25, 26, 27, 31, 41 and 71 the ECM lights the malfunction indicator lamp to warn the technician that malfunction has been detected. In this case, TE2 and E1 terminals on the data link connector 1 or 2 should be connected as shown later. (See page EG1–298). In the test mode, even if the malfunction is corrected, the malfunction code is stored in the ECM memory even when the ignition switch is off (except code Nos. 43 and 51). This also applies in the normal mode. The diagnostic mode (normal or test) and the output of the malfunction indicator lamp can be selected by connecting the TE1, TE2 and E1 terminals on the data link connector 1 or 2, as shown later. A test mode function has been added to the functions of the self–diagnostic system of the normal mode for the purpose of detecting malfunctions such as poor contact, which are difficult to detect in the normal mode. This function fills up the self–diagnosis system. The test mode can be implemented by the technician following the appropriate procedures of check terminal connection and operation described later. (See page EG1–298) EG1–297 5S–FE ENGINE – DIAGNOSIS SYSTEM Diagnosis Inspection (Normal Mode) MALFUNCTION INDICATOR LAMP CHECK 1. The Malfunction indicator lamp will come on when the ignition switch is turned ON and the engine is not run– ning. HINT: If the malfunction indicator lamp does not light up, proceed to troubleshooting of the combination meter (See page BE–64). 2. When the engine is started, the malfunction indicator lamp should go off. If the light remains on, the diagnosis system has detected a malfunction or abnormality in the system. DIAGNOSTIC TROUBLE CODE CHECK 1. Turn ignition switch on. 2. Using SST, connect terminals between TE1 and E1 of data link connector 1 or 2. SST 09843–18020 3. Read the diagnostic trouble code from malfunction indi– cator lamp. HINT: If a diagnostic trouble code is not output, check the TE1 terminal circuit (See page EG1–430). As an example, the blinking patterns for codes;normal, 12 and 31 are as shown on the illustration. 4. Check the details of the malfunction using the diagnostic trouble code table on page EG1–300. 5. After completing the check, disconnect terminals TE1 and E1, and turn off the display. HINT: I n the event of 2 or more malfunction codes, indication will begin from the smaller numbered code and continue in order to the larger. EG1–298 5S–FE ENGINE – DIAGNOSIS SYSTEM Diagnosis Inspection (Test Mode) Compared to the normal mode, the test mode has high sens– ing ability to detect malfunctions. It can also detect malfunctions in the starter signal circuit, the IDL contact signal of the throttle position sensor, air condi– tioning signal and Park/Neutral Position switch signal. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the test mode. DIAGNOSTIC TROUBLE CODE CHECK 1. Initial conditions. (a) Battery voltage 11 V or more. (b) Throttle valve fully closed. (c) Transmission in neutral position. (d) Air conditioning switched off. 2. Turn ignition switch off. 3. Using SST, connect terminals TE2 and E1 of data link connector 1 or 2. SST 09843–18020 4. Turn ignition switch on. HINT: • To confirm that the test mode is operating, check that the malfunction indicator lamp flashes when the igni– tion switch is turned to ON. • If the malfunction indicator lamp does not flash, pro– ceed to troubleshooting of the TE2 terminal circuit on page EG1–430. 5. Start the engine. 6. Simulate the conditions of the malfunction described by the customer. 7. After the road test, using SST, connect terminals TE1 and E1 of data link connector 1 or 2. SST 09843–18020 8. Read the diagnostic trouble code on malfunction indica– tor lamp on the combination meter (See page EG1–297). 9. After completing the check, disconnect terminals TE1, TE2 and E1, and turn off the display. HINT: • The test mode will not start if terminals TE2 and E1 are connected after the ignition switch is turned on. • When vehicle speed is 3 mph (5 km/h) or below, diagnostic trouble code “42” (Vehicle speed signal) is output, but this is not abnormal. • When the engine is not cranked, diagnostic trouble code “43” (Starter signal) output, but this is not ab– normal. • When the automatic transmission shift lever is in the “D”, “2”, “L” or “R” shift position, or when the air conditioning is on or when the accelerator pedal is depressed, code “51” (Switch condition signal) is output, but this is not abnormal. EG1–299 5S–FE ENGINE – DIAGNOSIS SYSTEM DIAGNOSTIC TROUBLE CODE CHECK USING TOYOTA HAND–HELD TESTER 1. Hook up the TOYOTA hand–held tester to the DLC2. 2. Read the diagnostic trouble codes by following the prompts on the tester screen. Please refer to the TOYOTA hand–held tester operator’s manual for further details. DIAGNOSTIC TROUBLE CODE CLEARANCE 1. After repair of the trouble areas, the diagnostic trouble code retained in the ECM memory must be cleared out by removing the E F I fuse (15A) from J/13 No. 2 for 10 seconds or more, with the ignition switch OFF. HINT: • Cancellation can also be done by removing the battery negative (–) terminal, but in this case, other memory systems (clock, etc.) will also be cancelled out. • If it is necessary to work on engine components requir– ing removal of the battery terminal, a check must first be made to see if a diagnostic trouble code has been recorded. 2. After cancellation, road test the vehicle to check that a normal code is now read on the malfunction indicator lamp. If the same diagnostic trouble code appears, it indicates that the trouble area has not been repaired thoroughly. ECM DATA MONITOR USING TOYOTA HAND–HELD TESTER 1. Hook up the TOYOTA hand–held tester to the D LC2. 2. Monitor the ECM data by following the prompts on the tester screen. HINT: TOYOTA hand–held tester has a “Snapshot” function which records the monitored data. Please refer to the TOYOTA hand–held tester operator’s manual for further details. ECM TERMINAL VALUES MEASUREMENT USING TOYOTA BREAK–OUT–BOX AND TOYOTA HAND–HELD TESTER 1. Hook up the TOYOTA break–out–box and TOYOTA hand–held tester to the vehicle. 2. Read the ECM input/output values by following the prompts on the tester screen. HINT: TOYOTA hand–held tester has “Snapshot” func– tion. This records the measured values and is effective in the diagnosis of intermittent problems. Please refer to the TOYOTA hand–held tester/Toyota break–out–box operator’s manual for further details. EG1–300 5S–FE ENGINE – DIAGNOSTIC TROUBLE CODE CHART DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may not be exactly same as your reading due to type of the instruments or other factors. DTC No. Number of MIL Blinks Circuit Diagnostic Trouble Code Detecting Condition Normal No code is recorded. G, NE Signal Circuit (No. 1) (Exc. California spec.) No NE signal to ECM within 2 sec. or more after cranking. G, N E Signal Circuit (No. 1) (Only for California spec,) No G signal to ECM for 3 sec. or more with engine speed between 600 rpm and 4,000 rpm. No N E or G 1 and G2 signal to ECM for 2 sec. or more after cranking. Open in G (–) circuit No NE signal to ECM for 0.3 sec. or more at 1,500 rpm or more. G, NE Signal Circuit (No. 2) No G signal to ECM while NE signal is input 4 times to ECM when engine speed is between 500 rpm and 4,000 rpm. * No N E signal to ECM for 0.1 sec. or more at 1,000 rpm or more. * NE signal does not pulse 12 times to ECM during the interval between G1 and G2 pulses. Ignition Signal Circuit No IGF signal to ECM for 4 consecutive IGT signals. * No IGF signal to ECM for 8 consecutive IGT signals. A/T Control Signal *,* : See page EG1–306 Fault in communications between the engine CPU and A/T CPU in the ECM EG1–301 5S–FE ENGINE – DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check in test mode, check the circuit for that code listed in the table below (Proceed to the page given for that circuit). Trouble Area Malfunction Indicator Lamp*
Normal Mode Memory* See page Test Mode EG1–336 • Open or short in NE, G circuit • Distributor • Open or short in STA circuit 9 ECM N.A. EG1–339 N.A. N.A. • Open or short in NE circuit • Distributor • ECM E G –343 N.A. N.A. • Open or short in IGF or IGT circuit from igniter to ECM • Igniter • ECM N.A. EG1–344 • ECM N.A. EG1–351 *
,*: See page EG1–306 EG1–302 5S–FE ENGINE DTC No. Number of MIL Blinks Circuit Main Oxygen Sensor Signal – DIAGNOSTIC TROUBLE CODE CHART Diagnostic Trouble Code Detecting Condition Main oxygen sensor signal voltage is reduced to between 0.35 V and 0.70 V for 60 sec. under conditions (a) ∼ (d). (2 trip detection logic) *5 (a) Engine coolant temp.: 80C (176F) or more. (b) Engine speed: 1,500 rpm or more. (c) Load driving (Ex. A/T in overdrive (5th for M/T), A/C ON, Flat road, 50 mph (80 km/h)). (d)Main oxygen sensor signal voltage: Alternating above and below 0.45 V. Engine Coolant Temp. Sensor Signal Open or short in engine coolant temp. sensor circuit for 0.5 sec. or more. Intake Air Temp. Sensor Signal Open or short in intake air temp. sensor circuit for 0.5 sec. or more. (1) Main oxygen sensor voltage is 0.45 V or less (lean) for 90 sec. under conditions (a) and (b). (2 trip detection logic)* (a) Engine coolant temp.: 60C (140F) or more. (b) Engine speed: 1,500 rpm or more. Air–Fuel Ratio Lean Malfunction (2) Engine speed varies by more than 15 rpm over the preceding crankshaft position period during a period of 50 sec. or more under conditions (a) and (b). (2 trip detection logic)* (a) Engine speed: Idling (b) Engine coolant temp.: 60C (140F) or more. *: See page EG1–307 EG1–303 5S–FE ENGINE – DIAGNOSTIC TROUBLE CODE CHART Malfunction Indicator Lamp*
Trouble Area Normal Mode • • Main oxygen sensor circuit Main oxygen sensor Memory‘ See page Test Mode EG1–352 • • • Open or short in engine coolant temp. sensor circuit Engine coolant temp. sensor ECM EG1–356 • • • Open or short in intake air temp. sensor circuit Intake air temp. sensor ECM EG1–360 • • • • Open or short in main oxygen sensor circuit Main oxygen sensor ignition system ECM • • • Open or short in injector circuit Fuel line pressure (injector leak, blockage) Mechanical system malfunction (skipping teeth of timing belt) Ignition system Compression pressure (foreign object caught in valve) Air leakage ECM • • • • EG1–363 *
,*: See page EG1–306 EG1–304 5S–FE ENGINE DTC No. Number of MIL Blinks Circuit Air–Fuel Ratio Rich Malfunction – DIAGNOSTIC TROUBLE CODE CHART Diagnostic Trouble Code Detecting Condition Engine speed varies by more than 15 rpm over the preceding crankshaft position period during a period of 50 sec. or more under conditions (a) and (b), (2 trip detection logic)* (a) Engine speed: Idling (b) Engine coolant temp.:60C (140F) or more. Sub Oxygen Sensor Signal Main oxygen sensor signal is 0.45 V or more and sub oxygen sensor signal is 0.45 V or less under conditions (a) and (b). (2 trip detection logic)* (a) Engine coolant temp.: 80C (176F) or more. (b) Accel. pedal: Fully depressed for 2 sec. or more. Manifold Absolute Pressure Sensor Signal Open or short in manifold absolute pressure sensor circuit for 0.5 sec. or more. Throttle Position Sensor Signal Open or short in throttle position sensor circuit for 0.5 sec. or more. No–1 Vehicle Speed Sensor Signal (for A/T) All conditions below are detected continuously for 8 sec. or more. (a) No.1 vehicle speed sensor signal: 0 mph (km/h) (b) Engine speed: 3,100 rpm or more. (c) Park/Neutral position switch: OFF All conditions below are detected continuously for 8 sec. or more. No.1 Vehicle Speed Sensor Signal (for M /T) *: See page EG1–307 (a) No.1 vehicle speed sensor signal: 0 mph (km/h) (b) Engine speed: Between 3,100 rpm and 5,000 rpm. (e) Engine coolant temp.: 80C (176F) or more. (d) Load driving. EG1–305 5S–FE ENGINE – DIAGNOSTIC TROUBLE CODE CHART Malfunction Indicator Lamp*
Trouble Area Normal Mode • • • Memory* See page Test Mode • • • • Open or short in injector circuit Fuel line pressure (injector leak, blockage) Mechanical system malfunction (skipping teeth of timing belt) Ignition system Compression pressure (foreign object caught in valve) Air leakage ECM • • • Open or short in sub oxygen sensor circuit Sub oxygen sensor ECM EG1–369 • • • Open or short in manifold absolute pressure sensor circuit. Manifold absolute pressure sensor ECM EG1–372 • • • Open or short in throttle position sensor circuit Throttle position sensor ECM • • • • Open or short in No.1 vehicle speed sensor circuit No.1 vehicle speed sensor Combination meter ECM *
,*: See page EG1–306 EG1–363 EG1–376 OFF OFF EG1–380 EG1–306 5S–FE ENGINE DTC No. Number of MIL Blinks – DIAGNOSTIC TROUBLE CODE CHART Diagnostic trouble Code Detecting Condition Circuit Starter Signal No starter signal to ECM. Knock Sensor Signal Open or short in knock sensor circuit with engine speed between 1,200 rpm and 6,000 rpm. EG R System Malfunction EGR gas temp. is 70C (158F) or below for 50 sec. under conditions (a) and (b). (2 trip detection logic)* (a) Engine coolant temp.: 80C (176F) or more. (b) EGR operation possible (Ex. A/T in 3rd speed (5th for M/T), 55 – 60 mph (88 – 96 km/h), Flat road). (1) Switch Condition Signal 3 sec. or more after engine starts with closed throttle position switch OFF (IDL). (2) * Park/Neutral switch OFF (PNP). (Shift position in “R”, “D”, “2”, or “L” positions). (3) A/C switch ON. *1; “ON” displayed in the diagnosis mode column indicates that the Malfunction Indicator Lamp is lighted up when a malfunction is detected. “OFF” indicates that the “CHECK” does not light up during malfunction diagnosis, even if a malfunction is detected. “N.A.” indicates that the item is not included in malfunction diagnosis. *2; “O” in the memory column indicates that a diagnostic trouble code is recorded in the ECM memory when a malfunction occurs. “X” indicates that a diagnostic trouble code is not recorded in the ECM memory even if a malfunction occurs. Accordingly, output of diagnostic results in normal or test mode is performed with the IG switch ON. *3; Only for California specification vehicles. *4; Only vehicles with A/T. EG1–307 5S–FE ENGINE Trouble Area • • Open or short in starter signal circuit Open or short in ignition switch or starter relay circuit ECM • • • Open or short in knock sensor circuit Knock sensor (looseness). ECM • • • • • open in EGR gas temp. sensor circuit Short in VSV circuit for EGR EGR hose disconnected, valve stuck Clogged EGR gas passage ECM • • • • • Throttle position sensor IDL circuit Accelerator pedal and cable Park/Neutral Position switch circuit A/C switch circuit ECM – DIAGNOSTIC TROUBLE CODE CHART Malfunction Indicator Lamp*
Memory* See page Normal Mode Test Mode N.A. OFF EG1–383 N.A. EG1–385 EG1–390 N.A. OFF EG1–396 *5: This indicates items for which “2 trip detection logic” is used. With this logic, when a logic malfunction is first detected, the malfunction is temporarily stored in the ECM memory. If the same case is detected again during the second drive test, this second detection causes the Malfunction Indicator Lamp to light up. The 2 trip repeats the same mode a 2nd time. (However, the IG switch must be turned OFF between the 1st trip and 2nd trip), In the Test Mode, the Malfunction Indicator Lamp lights up the 1st trip a malfunction is detected. EG1–308 5S–FE ENGINE – FAIL–SAFE CHART FAIL–SAFE CHART If any of the following codes is recorded, the ECM enters fail–safe mode. Fail–Safe Operation DTC No. Fail–Safe Deactivation Conditions Fuel cut 1 IGF detected in consecutive 2 (4*) ignitions. Torque control prohibited. Returned to normal condition. THW is fixed at 80
C (176
F). Returned to normal condition. THA is fixed at 20
C (68
F). Returned to normal condition. • • • Ignition timing fixed at 5
BTDC. Injection time fixed Starting ..... 12.1 m sec. I D L 0 N ..... 3.3 m sec. IDL OFF .... 6.1 m sec. Intake manifold vacuum is fixed at 46.7 kPa. (350 mmHg, 13.8 inHg) Returned to normal condition. VTA1 is fixed at 0
. The following must each be repeated at least 2 time consecutively. • 0.1 V
VTA
0.95 V • IDL : ON Max. timing retardation. IG switch OFF. *: Only for California specification vehicles. Back–Up Function If there is trouble with the program in the ECM and the ignition signals (IGT) are not output from microcomputer the ECM controls fuel injection and ignition timing at predetermined levels as a back–up function to make it possible to continue to operate the vehicle. Furthermore, the injection duration is calculated from the starting signal (STA) and the throttle position signal (IDL). Also, the ignition timing is fixed at the initial ignition timing, 5
BTDC, without relation to the engine speed. HINT: If the engine is controlled by the back–up function, the malfunction indicator lamp lights up to warn the driver of the malfunction but the diagnostic trouble code is not output. EG1–309 5S–FE ENGINE – CHECK FOR MOMENTARY INTERRUPTION CHECK FOR MOMENTARY INTERRUPTION DTC Circuit G, NE signal circuit (No.2) Engine coolant temp. sensor circuit Intake air temp. sensor circuit Manifold absolute pressure sensor circuit As described in the preceding paragraph, abnormality detec– tion ability in the test mode is increased compared to that in the normal mode, so that when momentary interruptions or momentary shorts occur in the ECM signal circuits (G, NE, THW, THA, PIM, VTA) shown in the table below, the appro– priate diagnostic trouble code is output. Accordingly, when the diagnostic trouble codes shown in the table below (13, 22, 24, 31, 41) are output during the diag– nostic trouble code check, and inspection of the appropriate circuits reveals no abnormality, perform the check for momen– tary interruption as described below. By performing the check for momentary interruption, the place where momentary interruptions or momentary shorts are occurring due to poor contacts can be isolated. Throttle position sensor circuit CLEAR DIAGNOSTIC TROUBLE CODES See page EG1–299. SET TEST MODE 1. With the ignition switch off, using SST, connect the ter– minals TE2 and E1 of the data link connector 1 and 2. SST 09843–18020 2. Start the engine and check to see the malfunction indica– tor lamp to go off. PERFORM A SIMULATION TEST Using the symptom simulation (See page IN –24), apply vibra– tion to and pull lightly on the wire harness, connector or terminals in the circuit indicated by the malfunction code. In this test, if the malfunction indicator lamp light up, it indi– cates that the place where the wire harness, connector or terminals being pulled or vibrated has faulty contact. Check that point for loose connections, dirt on the terminals, poor fit or other problems and repair as necessary. HINT: After cancelling out the diagnostic trouble code in memory and set the test mode, if the malfunction indicator lamp does not go off after the engine is started, check thor– oughly for faulty contact, etc., then try the check again. If the malfunction indicator lamp still does not go off, check and replace ECM. EG1–310 5S–FE ENGINE – BASIC INSPECTION BASIC INSPECTION When the normal code is displayed in the diagnostic trouble code check, troubleshooting should be performed in the order for all possible circuits to be considered as the causes of the problems. In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine troubleshooting. Is battery positive voltage 11 V or more when engine is stopped? YES Charge or replace battery. Is engine cranked ? YES Proceed to matrix chart of problem symptoms on page EG1–327. Does engine start YES Go to step Check air filter. Remove air filter. Visually check that the air filter is not excessively damaged or oily. If necessary, clean the air filter with compressed air. First blow from inside thoroughly, then blow off outside of the air filter. Repair or replace. Go to step EG1–311 5S–FE ENGINE – BASIC INSPECTION Check idle speed. (1) Shift transmission into “N” position or neutral. (2) Warm up engine at normal operating temperature. (3) Switched off all accessories. (4) Switched off air conditioning. (5) Connect tachometer test probe to terminal IG (–) of data link connector 1, and set the tachometer to the 4–cylinder range. Check idle speed. Idle speed: 700 ~ 800 rpm • NEVER allow tachometer test probe to touch ground as it could result in damage to igniter and/or ignition coil. • As some tachometers are not compatible with this ignition system, we recommended that you confirm compatibility of your unit before use. Proceed to matrix chart of problem symptoms on page EG1–327. Check ignition timing. (1) Shift transmission into “N” position or neutral. (2) Warm up engine at normal operating temperature. (3) Keep the engine speed at idle. (4) Using SST, connect terminals TE1 and E1 of data link connector 1. SST 09843–18020 (5) Using a timing light, connect the tester to No. 1 high–tension cord. Check ignition timing. Ignition timing: 10
BTDC at idle Proceed to page IG–19, 38* and continue to troubleshoot. *Except California specification vehicles. Proceed to matrix chart of problem symptoms on page EG1–327. EG1–312 5S–FE ENGINE – BASIC INSPECTION Check fuel pressure. (1) Be sure that fuel is enough in tank. (2) Turn ignition switch on. (3) Using SST, connect terminals FP and + B of data link connector 1. SST 09843–18020 Check for fuel pressure in the return hose when it is pinched off. At this time, you will hear fuel return noise. Never make a mistake with the terminal con– nection position as this will cause a malfunc– tion. Proceed to page EG1–178 and continue to troubleshoot. Check for spark. Disconnect the high–tension cord from the distributor and, hold the end about 12.5 mm (1/2”) from the ground, see if spark occurs while the engine is being cranked. To prevent excessive fuel injected from the injectors during this test, don’t crank the engine for more than 1–2 seconds at a time. Proceed to page IG–6, 26* and continue to troubleshoot. * : Except California specification vehicles. Proceed to matrix chart of problem symptoms on page EG1–327. EG1–313 5S–FE ENGINE PARTS LOCATION – PARTS LOCATION EG1–314 5S–FE ENGINE – WIRING DIAGRAM WIRING DIAGRAM Except California specification vehicles. EG1–315 5S–FE ENGINE – WIRING DIAGRAM EG1–316 5S–FE ENGINE – WIRING DIAGRAM WIRING DIAGRAM (Cont’d) Only for California specification vehicles. EG1–317 5S–FE ENGINE – WIRING DIAGRAM EG1–318 5S–FE ENGINE – TERMINALS OF ECM TERMINALS OF ECM When measuring the voltage or resistance of the connector part of the ECM, always insert the test probe into the connector from the wire harness side. ECM (Except California specification vehicles with M/T) Terminal No. Symbol E11– 1 ISCV Connection Terminal No. Connection Symbol VSV for A/C Idle up Starter relay Injectors (No.1 and No.3) Igniter Power ground Distributor Distributor Distributor Distributor IAC valve IAC valve EG1–319 5S–FE ENGINE Terminal No. Symbol Connection – TERMINALS OF ECM Terminal No. Symbol Connection Throttle position sensor Igniter EG R gas temp. sensor VSV for EG R ECM ground Data link connector 1 and 2 Injectors (No.2 and No.4) Sensor ground Power ground EFI main relay Sub oxygen sensor Battery Manifold absolute pressure sensor A/C amplifier Intake air temp. sensor Circuit opening relay Engine coolant temp. sensor Knock sensor A/C amplifier Main oxygen sensor EFI main relay Data link connector 1 and 2 Malfunction indicator lamp Data link connector 1 Sensor ground Throttle position sensor • Manifold absolute pressure sensor • Throttle position sensor No.1 vehicle speed sensor • Defogger relay • Taillight relay EG1–320 5S–FE ENGINE – TERMINALS OF ECM TERMINAL OF ECM (Cont’d) ECM (California specification vehicles and except California specification vehicles with A/T) Terminal Symbol No.* Connection Terminal No.* Connection Symbol A/T SL solenoid Distributor A/T No.1 solenoid Distributor Igniter Distributor Igniter Distributor VSV for A/C Idle up VSV for EG R VSV for fuel pressure control No.4 injector IAC valve No.3 injector IAC valve Power ground No.2 injector • • No.2 and No.4 injectors No.1 injector Manifold absolute pressure sensor Throttle position sensor Manifold absolute pressure sensor No.1 and No.3 injectors Power ground Intake air temp. sensor ECM ground Engine coolant temp. sensor A/T No,2 solenoid Sub oxygen sensor Main oxygen sensor *
: Only for California specification vehicles. *: Except California specification vehicles with A/T. EG1–321 5S–FE ENGINE Terminal Symbol No. Connection Data link connector 2 – TERMINALS OF ECM Terminal Symbol No. Connection O/D main switch Data link connector 1 Sensor ground No.1 vehicle speed sensor EGR gas temp. sensor A/C amplifier Throttle position sensor Starter relay Throttle position sensor EFI main relay Knock sensor EFI main relay Data link connector 1 and 2 Circuit opening relay Data link connector 1 and 2 Sensor ground Battery • • Defogger relay Taillight relay Park/neutral position switch Park/neutral position switch • • Stoplight switch Stoplight Cruise control ECU Malfunction indicator lamp A/C amplifier • Park/neutral position switch Park/neutral position switch *
: Only for California specification vehicles. *: Except California specification vehicles with A/T. EG1–322 5S–FE ENGINE – STANDARD VALUE OF ECM TERMINALS STANDARD VALUE OF EC TERMINALS ECM (Except California specification vehicles with M/T) Symbols (Terminals No.) Wiring Color STD Voltage (V) Condition Always IG switch ON IG switch ON IG switch ON and apply vacuum to the throttle opener. Throttle valve fully closed. IG switch ON Throttle valve fully open IG switch 0 N Throttle valve fully closed IG switch ON Throttle valve fully open IG switch ON Idling Idling, Intake air temp. 20C (68F) Idling, Engine coolant temp, 80C (176F) IG switch ON Pulse generation Idling Pulse generation Idling (See page EG1–347) Below 2.0 IG switch ON Pulse generation (See page EG1–347) Idling Pulse generation Idling (See page EG1–336) Pulse generation Idling (See page EG1–336) EG1–323 5S–FE ENGINE Symbols (Terminals No.) Wiring Color – STANDARD VALUE OF ECM TERMINALS STD Voltage (V) Condition IG switch ON Maintain engine speed at 2,500 rpm for 2 minutes after warming up then return to idling Maintain engine speed at 2,500 rpm for Pulse generation (See page EG1–355) 2 minutes after warming up lG switch ON Pulse generation Idling (See page EG1–389) Pulse generation IG switch ON (See page EG1–380) Rotate driving wheel slowly IG switch ON IG switch ON Idling IG switch ON A/C switch ON (at idling) A/C switch OFF Idling, A/C switch ON Idling, A/C switch OFF EG1–324 5S–FE ENGINE – STANDARD VALUE OF ECM TERMINALS STANDARD VALUE OF ECM TERMINALS (Cont’d) ECM (California specification vehicles and except California specification vehicles with A/T) Symbols (Terminals No.)*3 Wiring Color STD Voltage (V) Condition Always IG switch ON lG switch ON IG switch ON and apply vacuum to the throttle opener. Throttle valve fully closed. IG switch ON Throttle valve fully open IG switch ON Throttle valve fully closed IG switch ON Throttle valve fully open IG switch ON Idling Idling, Intake air temp. 20C (68F) Idling, Engine coolant temp. 80C (176F) IG switch ON Pulse generation (See page EG1–410) Idling Pulse generation (See page EG1–347) Idling Below 2.0 IG switch ON Pulse generation (See page EG1–347)Idling Pulse generation Idling (See page EG1–341) Pulse generation Idling (See page EG1–341) Pulse generation Idling (See page EG1–336) Pulse generation (See page EG1–336) Idling *
: Only for California specification vehicles. *: Except California specification vehicles with A/T. EG1–325 5S–FE ENGINE Symbols (Terminals No.)* Wiring Color – STANDARD VALUE OF ECM TERMINALS STD Voltage (V) Condition IG switch ON Maintain engine speed at 2,500 rpm for 2 minutes after warming up then return to idling Pulse generation Maintain engine speed at 2,500 rpm for (See page EG1–355) 2 minutes after warming up IG switch ON Pulse generation (See page EG1–389) Idling IG switch ON Other shift position in “P”, “N” position IG switch ON Shift position in “P”, “N” position IG switch ON Pulse generation (See page EG1–380) Rotate driving wheel slowly IG switch ON IG switch O N Idling IG switch ON IG switch ON IG switch ON O/D main switch pushed in IG switch ON 0/D main switch pushed out A/C switch ON (At idling) A/C switch OFF Idling, A/C switch ON Idling, A/C switch OFF IG switch ON Restarting at high engine coolant temp. *
: Only for California specification vehicles. *: EG1–326 5S–FE ENGINE – REFERENCE VALUE OF ECM DATA REFERENCE VALUE OF ECM DATA HINT: ECM data can be monitored by TOYOTA hand–held tester. 1. Hook up the TOYOTA hand–held tester to the DLC2. 2. Monitor ECM data by following the prompts on the tester screen. Please refer to the TOYOTA hand–held tester operator’s manual for further details. REFERENCE VALUE Item Inspection condition Reference value INJECTOR Engine cold to hot Engine idling at normal operating temp. IGNITION Increase engine speed Gradually increases IAC DUTY Engine idling at normal operating temp. 30∼60% Gradually decreases Approx. 2 ∼ 5 msecs RPM kept stable (Comparison with tachometer) No great changes MAP Engine idling at normal operating temp. increase engine load Approx. 180 ∼ 280 mm Hg Gradually increases ECT Engine at normal operating temp. 75 – 95
C (185 – 203
F) *1 Closed throttle position Wide open throttle From closed throttle position to wide open throttle Below 5
Above 70
Gradually increases VEHICLE SPD During driving (Comparison with speedometer) No large differences TARGET A/F L Engine idling at normal operating temp. 2.50± 1.25 V *2 ENGINE SPEED THROTTLE A/F FB LEFT RPM stable at 2,500 rpm with normal operating temp. STA SIGNAL During cranking CTP SIGNAL Closed throttle position A/C SIGNAL A/C switch ON PNP SIGNAL *3 OxL When shifting from “P” or “N” position into a position other than “P” or “N” PRM stable at 2,500 rpm with normal operating temp. G EAR RICH LEAN is repeated *1: If the engine coolant temp, sensor circuit is open or shorted, the ECM assumes an engine coolant temp, value of 80
C (176
F). *2: When feedback control is forbidden, 0 V is displayed, *3: A/T only. EG1–327 5S–FE ENGINE – MATRIX CHART OF PROBLEM SYMPTOMS MATRIX CHART OF PROBLEM SYMPTOMS Does not start Engine does not crank No initial combustion No complete combustion Difficult to start Under normal condition Cold engine Hot engine Incorrect first idle Poor Idling High engine idle speed Low engine idle speed Rough idling Poor Driveability Hunting Hesitation/Poor acceleration Muffler explosion (after fire) Surging Soon after starting Engine Stall After acceleration pedal depressed After acceleration pedal released During A/C operation When N to D shift *: Except California specification vehicles. IG–6,26* IG–8,28* lG–10,30* IG–11,30 EG1–23 AX1–68 IN–36 Spark plug Ignition coil Distributor Compression A/T faulty Engine control module EG1–419 Fuel system circuit ST–19,21 EG1–415 IAC valve circuit Starter and Starter relay EG1–410 Ignition signal circuit (Spark test) EG1–408 Back up power source circuit Injector circuit EG1 –424 EG1–403 ECM power source circuit EG1–428 EG1–400 Park/Neutral position switch circuit A/C cut control circuit EG1–396 Switch condition signal circuit VSV circuit for fuel pressure control EG1–390 EG R system Symptom EG1–383 Suspect area Starter signal circuit See page Manifold absolute pressure sensor circuit EG1–372 When the malfunction code is not confirmed in the diagnostic trouble code check and the problem still can not be confirmed in the basic inspection, then proceed to this step and perform troubleshooting according to the numbered order given in the table below. EG1–328 5S–FE ENGINE – LOCATION OF CONNECTORS LOCATION OF CONNECTORS Location of Connectors in Engine Compartment EG1–329 5S–FE ENGINE – LOCATION OF CONNECTORS EG1–330 5S–FE ENGINE – LOCATION OF CONNECTORS Location of Connectors in Instrument Panel EG1–331 5S–FE ENGINE !/B No.1 – LOCATION OF CONNECTORS EG1–332 5S–FE ENGINE – LOCATION OF CONNECTORS Location of Connectors in Instrument Panel (Cont’d) J/B No.1 J/B No.3 R/B No.1 R/B No.6 EG1–333 5S–FE ENGINE – Location of Connectors in Body Sedan Coupe LOCATION OF CONNECTORS EG1–334 5S–FE ENGINE – LOCATION OF CONNECTORS Location of Connectors in Body (Cont’d) Wagon 5S-FE ENGINE – -Memo EG1–336 5S–FE ENGINE – CIRCUIT INSPECTION CIRCUIT INSPECTION DTC 12 G NE Signal Circuit (No.1) (Exc. California spec.) CIRCUIT DESCRIPTION The distributor in the Engine Control System contains 3 pickup coils. The G signals inform the ECM of the standard crankshaft position. The NE signals inform the ECM of the crankshaft position and the engine speed. DTC No. Diagnostic Trouble Code Detecting Condition Trouble Area No N E signal to ECM with 2 sec. or more after cranking. No G signal to ECM for 3 sec. or more with engine speed between 600 rpm and 4,000 rpm. Reference • • • • Open or short in NE, G circuit Distributor Open or short in STA circuit ECM INSPECTION USING OSCILLOSCOPE • During cranking or idling, check waveforms between terminals G (+) and G (–), NE (+) and NE (–) of engine control module. HINT: The correct waveforms appear as shown in the illustration on the left. EG1–337 5S–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check resistance of each pickup coils in distributor. Replace distributor housing. Check for open and short in harness and connector between ECM and distributor. Repair or replace harness or connector. Check air gap. Replace distributor housing. Check and replace ECM. WIRING DIAGRAM EG1–338 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check resistance of each pickup coils in distributor. Disconnect distributor connector. Measure resistance between each terminal shown in table below. Resistance G Pickup Coil (G1 –G (–)) Cold 185 ~ 275
Hot 240 ~ 325
NE Pickup Coil (NE (+) – NE (–) ) Cold 370 ~ 550
Hot 475 ~ 650
“Cold” is from –10
C (14
F) to 50
C (122
F) and “Hot” is from 50
C (122
F) to 100
C (212
F). Replace distributor housing. Check for open and short in harness and connector between engine control module and distributor (See page IN–31). Repair or replace harness or connector. Check air gap. Remove distributor cap and rotor. Using a thickness gauge, measure the air gap be– tween the signal rotor and pickup coil projection. Air gap: 0.2 – 0.4 mm (0.008 – 0.006 in.) Replace distributor housing. Check and replace engine control module. EG1–339 5S–FE ENGINE – CIRCUIT INSPECTION DTC 12 G NE Signal Circuit (No.1) (Only for California spec.) CIRCUIT DESCRIPTION The distributor in the Engine Control System contains 3 pick–up coils (G1, G2 and NE). The G1, G2 signals inform the ECM of the standard crankshaft angle. The NE signals inform the ECM of the crankshaft angle and the engine speed. DTC No. Diagnostic Trouble Code Detecting Condition No NE or G1 and G2 signal to ECM for 2 sec. or more after cranking. Open in G (–) circuit. Trouble Area • • • • Open or short in NE, G circuit. Distributor Open or short in STA circuit. ECM EG1–340 5S–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check resistance of each pickup coils in distributor. Replace distributor. Check for open and short in harness and connector between ECM and distributor. Repair or replace harness or connector. Check air gap. Replace distributor. Check and replace ECM. WIRING DIAGRAM EG1–341 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check resistance of each pickup coils in distributor. Disconnect distributor connector. Measure resistance between each terminal shown in table below. Resistance “Cold” is from –10
C (14
F) to 50
C (122
F) and “Hot” is from 50
C (122
F) to 100
C (212
F). Reference INSPECTION USING OSCILLOSCOPE • During cranking or idling, check waveforms be– tween terminals G1, G2, NE and G O of engine control module. HINT: The correct waveforms appear as shown in the illustration on the left. Replace distributor. Check for open and short in harness and connector between engine control module and distributor (See page IN–31). Repair or replace harness or connector. EG1–342 5S–FE ENGINE – CIRCUIT INSPECTION Check air gap. Remove distributor cap & rotor. Using SST (G1 and G2 pickups) and a thickness gauge (NE pickup), measure the air gap between the signal rotor and pickup coil projection. SST 09240–00020 for G1 and G2 pickups Air gap: 0.2–0.5 mm (0.008–0.020 in.) Replace distributor housing assembly. Check and replace engine control module. EG1–343 5S–FE ENGINE – CIRCUIT INSPECTION DTC 13 G NE Signal Circuit (No.2) CIRCUIT DESCRIPTION Refer to G, NE signal circuit (No. 1) on page EG1–336, 339. DTC No. Trouble Area Diagnostic Trouble Code Detecting Condition No NE signal to ECM for 0.3 sec. or more at 1,500 rpm or more. No G signal to ECM while N E signal is input 4 times to ECM when engine speed is between 500 rpm and 4,000 rpm. * No NE signal to ECM for 0.1 sec. or more at 1,000 rpm or more. • • • Open or short in NE circuit Distributor ECM * NE signal does not pulse 12 times to ECM during the interval between G1 and G2 pulses. *: Only for California specification vehicles. DIAGNOSIS This code indicates that a momentary interruption of the G, N E signal from the distributor to the ECM has occurred, but that it is returned to normal. Note that although this problem may not necessarily appear at the time of inspection, it cannot be ignored because this diagnostic trouble code is output, indicating that there is or was a malfunction in the G, NE signal circuit; this “malfunction” is usually a loose connector. The distributor connector and the N E terminal of the ECM connector must therefore be checked for the following: 1. Loose connectors 2. Dirty connector terminals 3. Loose connector terminals EG1–344 5S–FE ENGINE – CIRCUIT INSPECTION DTC 14 Ignition Signal Circuit CIRCUIT DESCRIPTION The ECM determines the ignition timing, turns on Tr, at a predetermined angle (’*CA) before the desired ignition timing and outputs an ignition signal (IGT) “1” to the igniter. Since the width of the IGT signal is constant, the dwell angle control circuit in the igniter determines the time the control circuit starts primary current flow to the ignition coil based on the engine rpm and ignition timing one revolution ago, that is, the time the Tr2 turns on. When it reaches the ignition timing, the ECM turns Tr, off and outputs the IGT signal “O”. This turns Tr2 off, interrupting the primary current flow and generating a high voltage in the secondary coil which causes the spark plug to spark. Also, by the counter electromotive force generated when the primary current is interrupted, the igniter sends an ignition confirmation signal (IGF) to the ECM. The ECM stops fuel injection as a fail safe function when the lG F signal is not input to the ECM. DTC No. Trouble Area Diagnostic Trouble Code Detecting Condition • Open or short in IG F or IGT circuit from No IGF signal to ECM for 4 (8*2) consecutive IGT signals. WIRING DIAGRAM igniter to ECM. • Igniter • ECM EG1–345 5S–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check for spark. Check for open and short in IGF signal circuit between igniter and ECM. Repair or replace harness or connector. Check voltage of terminal I G F. Replace igniter. Check and replace ECM. Check voltage of terminal IGT. Check voltage of igniter power source. Check and repair igniter power source circuit. Check for open and short in primary coil circuit. Repair or replace harness or connector. Check ignition coil. Replace ignition coil. Replace igniter. Check voltage of terminal IGT (Disconnect igniter connector). Replace igniter. Check for open and short in IGT signal circuit between igniter and ECM. Repair or replace harness or connector. Check and replace ECM. EG1–346 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check for spark. Disconnect the high–tension cord from the distributor, hold its end about 12.5 mm (11 /2”) from the ground, see if spark occurs while the engine is being cranked. Spark should be generated. To prevent excessive fuel injected from the injectors during this check, don’t crank the engine for more than 1 – 2 seconds at a time. Go to step Check for open and short in harness and connector in IGF signal circuit between engine control module and igniter (See page IN–31). Repair or replace harness or connector. Disconnect igniter connector and check voltage between terminal IGF of engine control module connector and body ground. (1) Disconnect igniter connector. (2) Remove glove compartment. (See page EG1–234). (3) Turn ignition switch on. Measure voltage between terminal IGF of engine control module connector and body ground. Voltage: 4.5 ∼ 5.5 V Replace igniter. Check and replace engine control module. EG1–347 5S–FE ENGINE – CIRCUIT INSPECTION Check voltage between terminal IGT of engine control module connector and body ground. Remove glove compartment. (See page EG1–234) . Measure voltage between terminal IGT of engine control module connector and body ground when engine is cranked. Voltage: 0.5 – 1.0 V (Neither 0 V nor 5 V) Reference INSPECTION USING OSCILLOSCOPE • During cranking or idling, check waveform between terminal IGT and E1 of engine control module. HINT: The correct waveform appears as shown in the illustration on the left, with rectangle waves. Go to step EG1–348 5S–FE ENGINE – CIRCUIT INSPECTION Check voltage between terminal 3 of igniter connector and body ground. Disconnect igniter connector. Measure voltage between terminal 3 of igniter connector and body ground, when ignition switch is turned to “ON” and “STA” position. Voltage: 9 ∼ 14 V Check and repair igniter power source circuit. Check for open and short in harness and connector between ignition switch and ignition coil, ignition coil and igniter (See page IN–31). Repair or replace harness or connector. EG1–349 5S–FE ENGINE – CIRCUIT INSPECTION Check ignition coil. For California spec. (1) Disconnect ignition coil connector. (2) Disconnect high–tension cord from ignition coil. Exc. California spec. (1) Disconnect distributor connectors. (2) Remove distributor cap and rotor. (3) Remove ignition coil dust cover. (1) Check primary coil. Measure resistance between the positive (+) and negative (–) terminals. (2) Check secondary coil. Measure resistance between the positive (+) and high–tension terminals. Resistance Primary Coil Cold Secondary Coil Cold Hot Hot “Cold” is from –10
C (14
F) to 50
C (122
F) and “Hot” is from 50
C (122
F) to 100
C (212
F). Replace ignition coil. Replace igniter. EG1–350 5S–FE ENGINE – CIRCUIT INSPECTION Disconnect igniter connector and check voltage between terminal IGT of engine control module connector and body ground. Disconnect igniter connector. Measure voltage between terminal IGT of engine control module connector and body ground when engine is cranked. Voltage: 0.5–1.0 V (Neither 0 V nor 5 V) Replace igniter. Check for open and short in harness and connector in IGT signal circuit between engine control module and igniter (See page IN–31). Repair or replace harness or connector. Check and replace engine control module. EG1–351 5S–FE ENGINE – CIRCUIT INSPECTION DTC 16 A–T Control Signal Malfunction CIRCUIT DESCRIPTION The signal from the A/T CPU retards the ignition timing of the engine during A/T shifting, thus momentarily reducing torque output of the engine for smooth clutch operation inside the transmission and reduced shift shock. DTC No. Trouble Area Diagnostic Trouble Code Detecting Condition Fault in communications between the engine CPU and A/T CPU in the ECM • ECM If the ECM detects the diagnostic trouble code “16” in memory, it prohibits the torque control of the A/T which performs smooth gear shifting. DIAGNOSTIC CHART Are there any other codes (besides Code 16) being output? Replace ECM. YES Go to relevant diagnostic trouble code chart. EG1–352 5S–FE ENGINE – CIRCUIT INSPECTION DTC 21 Main Oxygen Sensor Circuit CIRCUIT DESCRIPTION To obtain a high purification rate for the C0, HC and NOx components of the exhaust gas, a three– way catalytic converter is used, but for most efficient use of the three–way catalytic converter, the air–fuel ratio must be precisely controlled so that it is always close to the stoichiometric air–fuel ratio. The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air–fuel ratio. This characteristic is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air–fuel ratio. When the air–fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN condition (small electromotive force; 0 V). When the air–fuel ratio is RICHER than the stoichiometric air–fuel ratio the oxygen concentration in the exhaust gas is reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive force: 1 V). The ECM judges by the electromotive force from the oxygen sensor whether the air–fuel ratio is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the ECM is unable to perform accurate air–fuel ratio control. DTC No. Diagnostic Trouble Code Detecting Condition Main oxygen sensor signal voltage is reduced to between 0.35 V and 0.70 V for 60 sec. under conditions (a) – (d). (2 trip detection logic) * (a) Engine coolant temp. : 80
C (176
F) or more. (b) Engine speed : 1,500 rpm or more. (c) Load driving (EX. A/T in overdrive (5th for M/T), A/C ON, Flat road, 50 mph (80km/h)). (d) Main oxygen sensor signal voltage : Alternating above and below 0.45 V. *See page EG1–307 Trouble Area • Main oxygen sensor circuit. • Main oxygen sensor. EG1–353 5S–FE ENGINE – CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont’d) DIAGNOSIS TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern. (a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected. Malfunction: Main Oxygen Sensor Deterioration Disconnect the EFI fuse (15A) for 10 sec. or more, with IG switch OFF. Initiate test mode (Connect terminal TE2 and E1 of data link connector 1 or 2 with IG switch OFF). Start the engine and warm up with all ACC switch OFF. After the engine is warmed up, let it idle for 3 min. After performing the idling in (3) , perform gradual acceleration with in the range 1,300∼1,700 rpm (centered around 1,500 rpm) with the A/C switch ON and D position for A/T (5th for M /T). (Take care that the engine speed does not fall below 1,200 rpm when shifting. Gradually depress the accelerator pedal and keep it. Steady so that engine braking does not occur). Maintain the vehicle speed at 40 – 50 mph (64 – 80 km/h). Keep the vehicle running for 1 – 2 min. after starting acceleration. HINT: If a malfunction exists, the malfunction indicator lamp will light up after approx. 60 sec. from the start of acceleration. NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. EG1–354 5S–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Are there any other codes (besides code 21) being output ? Replace main oxygen sensor. WIRING DIAGRAM YES Go to relevant diagnostic trouble code chart. EG1–355 5S–FE ENGINE – CIRCUIT INSPECTION Reference INSPECTION USING OSCILLOSCOPE • With the engine racing (4,000 rpm) measure wave– form between terminals OX1 and E1 of engine con– trol module. HINT: The correct waveform appears as shown in the illustration on the left, oscillating between approx. 0.1 V and 0.9 V. If the oxygen sensor is deteriorated, the amplitude of the voltage is reduced as shown on the left. EG1–356 5S–FE ENGINE – CIRCUIT INSPECTION DTC 22 Engine coolant Temp. Sensor Circuit CIRCUIT DESCRIPTION The engine coolant temperature sensor senses the engine coolant temperature. A thermistor built in the sensor changes its resistance value according to the engine coolant temperature. The lower the engine coolant temperature, the greater the thermistor resis– tance value, and the higher the engine coolant tem– perature, the lower the thermistor resistance value (See Fig. 1.). The engine coolant temperature sensor is connected to the ECM (See next page). The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THW via a resistor R. That is, resistor R and the engine coolant tem– perature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant temperature, the potential at the ter– minal THW also changes. Based on this signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. If the ECM detects the diagnostic trouble code 22, it operates the fail safe function in which the engine coolant temper– ature is assumed to be 80
C (176
F). DTC No. Diagnostic Trouble Code Detecting Condition ( Reference ) Engine coolant Resistance Temp.
C (
F) (k
) Voltage (V) –20 (–4) 16.0 4.3 0 (32) 5.9 3.4 20 (68) 2.5 2.4 60 (140) 0.6 0.9 80 (176) 0.3 0.5 100 (212) 0.2 0.3 40 (104) Trouble Area • Open or short in engine coolant temp, Open or short in engine coolant temp. sensor circuit for 0.5 sec. or more. sensor circuit • Engine coolant temp. sensor • ECM EG1–357 5S–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART HINT If diagnostic trouble codes “22” (engine coolant temperature sensor circuit), “24” (intake air temperature sensor circuit), “31” (manifold absolute pressure sensor circuit) and “41” (throttle position sensor circuit) are output simultaneously, E2 (sensor ground) may be open, OK Check for momentary interruption Check voltage of sensor. Check for momentary interruption (See page EG1–309). Check resistance of sensor. Replace engine coolant temp. sensor. Check for open and short in harness and connector between ECM and engine coolant temp. sensor. Repair or replace harness or connector. Check and replace ECM. WIRING DIAGRAM EG1–358 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE HINT: If diagnostic trouble codes “22” (engine coolant temperature sensor circuit), “24” (intake air temperature sensor circuit), “31” (manifold absolute pressure sensor circuit) and “41 “ (throttle position sensor circuit) are output simultaneously, E2 (sensor ground) may be open, Check voltage between terminals THW and E2 of engine control module connector. (1) Remove glove compartment (See page EG1–234) (2) Turn ignition switch on. Measure voltage between terminals THW and E2 of engine control module connector. Engine Coolant Temp.
C (
F) 20 (68) ( Engine is cool ) 80 (176) (Engine is hot) Voltage 0.5 ∼ 3.4 V 0.2 ∼1.0 v Check for momentary interruption (See page EG1–309) EG1–359 5S–FE ENGINE – CIRCUIT INSPECTION Check engine coolant temp. sensor. Disconnect the engine coolant temp. sensor con– nector. Measure resistance between terminals. Resistance is within Acceptable Zone on chart. Engine coolant Resistance Temp.
C (
F) 20(68) 2 – 3 k
80(176) 0.2 – 0.4 k
Replace engine coolant temp. sensor. Check for open and short in harness and connector between engine control module and engine coolant temp. sensor (See page IN–31). Repair or replace harness or connector. Check and replace engine control module. EG1–360 5S–FE ENGINE – CIRCUIT INSPECTION DTC 24 Intake Air Temp. Sensor Circuit CIRCUIT DESCRIPTION The intake air temp. sensor is built into the air cleaner cap and senses the intake air temperature. The structure of the sensor and connection to the ECM is the same as in the engine coolant temp. sensor shown on page EG1–356. If the ECM detects the diagnostic trouble code “24”, it operates the fail safe function in which the intake air temperature is assumed to be 20
C (68
F) DTC No. Diagnostic Trouble Code Detecting Condition Open or short in intake air temp. sensor circuit for 0.5 sec. or more. Trouble Area • Open or short in intake air temp. sensor circuit. • Intake air temp. sensor • ECM DIAGNOSTIC CHART HINT: If diagnostic trouble codes “22” (engine coolant temperature sensor circuit), “24” (intake air temperature sensor circuit), “31” (manifold absolute pressure sensor circuit) and “41” (throt– tle position sensor circuit) are output simultaneously, E2 (sensor ground) may be open. Check voltage of sensor. Check for momentary interruption (See page EG1–309). Check resistance of sensor. Replace intake air temp. sensor. Check for open and short in harness and connector between ECM and intake air temp. sensor. Repair or replace harness or connector. Check and replace ECM. WIRING DIAGRAM EG1–361 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals THA and E2 of engine control module connector. (1) Remove glove compartment. (See page EG1–234) (2) Turn ignition switch on. Measure voltage between terminals THA and E2 of engine control module connector. Intake air temp. °C (°F) Voltage 20 (68) 0.5 ∼ 3.4 V 60 (140) 0.2 ∼ 1.0 V Check for momentary interruption (See page EG1–309). EG1–362 5S–FE ENGINE – CIRCUIT INSPECTION Check intake air temp. sensor. Disconnect the air temp. sensor connector. Measure resistance between terminals. Resistance is within Acceptable Zone on chart. Intake air temp. Resistance °C (° F) 2 –3k
20(68) 60 (140) 0.4 – 0.7 k
Replace intake air temp. sensor. Check for open and short in harness and connector between engine control module and intake air temp. sensor (See page IN–31). Repair or replace harness or connector. Check and replace engine control module. EG1–363 5S–FE ENGINE – CIRCUIT INSPECTION DTC 25 26 Air–Fuel Ratio Lean Rich Malfunction CIRCUIT DESCRIPTION The main oxygen sensor is located in the exhaust manifold. It indirectly determines whether the fuel mixture is rich or lean by detecting the concentration of oxygen present in the exhaust gas. DTC No. Diagnostic Trouble Code Detecting Condition (1) Main oxygen sensor voltage is 0.45 V or less (lean) for 90 sec. under conditions (a) and (b). (2 trip detection logic) * (a) Engine coolant temp.: 60
C (140
F) or more. (b) Engine speed: 1,500 rpm or more. (2) Engine speed varies by more than 15 rpm over the preceding crank position period during a period of 50 sec. or more under conditions (a) and (b). (2 trip detection logic) * (a) Engine speed: Idling (b) Engine coolant temp.: 60
C (140
F) or more. Trouble Area • • • • Open or short in main oxygen sensor circuit Main oxygen sensor Ignition system ECM • • • Open or short in injector circuit Fuel line pressure (injector leak, blockage) Mechanical system malfunction (skipping teeth of timing belt) Ignition system Compression pressure (foreign object caught in valve) Air leakage ECM • • • • Engine speed varies by more than 15 rpm over the preceding crank position period during a period of 50 sec. or more under conditions (a) and (b). (2 trip detection logic) * (a) Engine speed: Idling (b) Engine coolant temp.: 60
C (140
F) or more • • • • • • • *: See page EG1–307 Open or short in injector circuit Fuel line pressure (injector leak, blockage) Mechanical system malfunction (skipping teeth of timing belt) Ignition system Compression pressure (foreign object caught in valve) Air leakage ECM EG1–364 5S–FE ENGINE – CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont’d) DIAGNOSIS TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern. (a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected. Malfunction: Open or Short in Main Oxygen Sensor. Open or Short in Injector Circuit, Injector Leak or Blockage. H I NT: Before this test, check the feedback voltage for oxygen sensor. Disconnect the EFI fuse (15 A) for 10 sec. or more, with IG switch OFF. Initiate test mode (Connect terminal TE2 and E1 of data link connector 1 or 2 with IG switch OFF). Start engine and warm up. After the engine is warmed up, let it race at 2,500 rpm for 3 min. After performing the racing in (3) , perform idling 1 min. HINT: If a malfunction exists, the malfunction indicator lamp will light up during step (4). NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. EG1–365 5S–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART N G TypeΙΙ Check voltage of terminal VF1. NG Type I Check voltage of terminal OX1. Check for open and short in harness and connector. Repair or replace harness or connector. Check each item found to be a possible cause of problem. Repair or replace. Check compression. Repair or replace. Does malfunction disappear when a good main oxygen sensor is installed? YES Replace main oxygen sensor. Check and replace ECM. Check each item found to be a possible cause of problem. Repair or replace. Check compression. Repair or replace. Does malfunction disappear when a good main oxygen sensor is installed? Check and replace ECM. WIRING DIAGRAM Refer to page EG1–354 for the WIRING DIAGRAM. YES Replace main oxygen sensor. EG1–366 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals VF1 and E1 of data link connector 1. (1) Warm up engine at normal operating tem– perature. (2) Connect terminals TE1 and E1 of data link connector 1. (3) Connect positive prove to terminal VF1 and negative prove to terminal E1 of data link connector 1. (1) Warm up the oxygen sensor by running en– gine at 2,500 rpm for about 2 minutes. (2) Then, maintaining engine at 2,500 rpm, count how many times needle of voltmeter fluctuates between 0 and 5 V. Result Needle fluctuates of 8 times or more for every ten seconds NG Type Ι NG Type ΙΙ Continue at 0 V NG Type ΙΙ Continue at 5 V NG Type ΙΙ Go to step Check voltage between terminals OX1 and E1 of data link connector 1. Warm up engine at normal operating temperature. Measure voltage between terminals OX1 and E1 of data link connector 1 when engine is suddenly raced to full throttle. The voltage should be 0.5 V or higher at least once. Perform inspection within 1 second. Go to step EG1–367 5S–FE ENGINE – CIRCUIT INSPECTION Check for open and short in harness and connector between engine control module and main oxygen sensor, engine control module and data link connector 1 (See page IN–31). Repair or replace harness or connector. Check each item found to be a possible cause of problem. Check each circuit found to be a possible cause of trouble according to the results of the check in or . The numbers in the table below show the order in which the checks should be performed. Main oxygen sensor signal continue at OV. Possible Cause See page Faulty sensor installation. Injector circuit EG1–410 Misfire IG–6, 26* Valve timing EG1–36 Air leakage EG1–173 Fuel system EG1–419 Characteristics deviation in EG1–372 manifold absolute pressure sensor. Characteristics deviation in engine coolant temp. sensor. EG1–356 Characteristics deviation in intake air temp. sensor. EG1–360 *: Except California specification vehicles. Repair or replace. Check compression (See page EG1–23). Repair or replace. Does malfunction disappear when a good main oxygen sensor is installed? YES Check and replace engine control module. Replace main oxygen sensor. EG1–368 5S–FE ENGINE – CIRCUIT INSPECTION Check each item found to be a possible cause of problem. Check each circuit found to be a possible cause of trouble according to the results of the check in .The numbers in the table below show the order in which the checks should be performed. Main oxygen sensor signal continue at 5.0 V. Main oxygen sensor signal is normal. Possible Cause Injector circuit See page EG1–410 Misfire IG–6, 26* Valve timing EG1–36 Air leakage EG1–173 Fuel system EG1–419 Characteristics deviation in manifold absolute pressure sensor. EG1–372 Characteristics deviation EG1–356 in engine coolant temp. sensor. Characteristics deviation in intake air temp. sensor. x: Except California specification vehicles. Repair or replace. Check compression (See page EG1–23). Repair or replace. Does malfunction disappear when a good main oxygen sensor is installed? YES Check and replace engine control module. Replace main oxygen sensor. EG1–360 EG1–369 5S–FE ENGINE – CIRCUIT INSPECTION DTC 27 Sub Oxygen Sensor Circuit CIRCUIT DESCRIPTION The sub oxygen sensor is installed on the exhaust pipe. Its construction and operation is the same as the main oxygen sensor on page EG1–352. DTC No. Trouble Area Diagnostic Trouble Code Detecting Condition Main oxygen sensor signal is 0.45 V or more and sub oxygen sensor signal is 0.45 V or less under conditions (a) and (b). (2 trip detection logic) * (a) Engine coolant temp. : 80
C (1 76
F) or more. (b) Accel. pedal : Fully depressed for 2 sec. or more. * : See page EG1–307. • • • Open or short in sub oxygen sensor circuit. Sub oxygen sensor ECM EG1–370 5S–FE ENGINE – CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont’d) DIAGNOSIS TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern. (a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diagnos– tic trouble code is no longer detected. Malfunction: Open or Short in Sub Oxygen Sensor Disconnect the E F I fuse (15 A) for 10 sec. or more, with IG switch OFF. Initiate test mode (Connect terminals TE2 and E1 of data link connector 1 or 2 with I G switch OFF). Start the engine and warm up, with all ACC switch OFF. After the engine is warmed up, let it drive at 50 ∼ 55 mph (80 ∼ 88 km/h) for 10 min. or more. After driving, stop at a safe place and perform idling for 2 min. or less. After performing the idling in (4) , perform acceleration to 60 mph (96 km/h) with the throttle valve fully open. HINT: If a malfunction exists, the malfunction indicator lamp will light up during step. NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. EG1–371 5S–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Are there any other codes (beside Code 27) being output? Replace sub oxygen sensor. WIRING DIAGRAM YES Go to relevant diagnostic trouble code chart. EG1–372 5S–FE ENGINE – CIRCUIT INSPECTION DTC 31 Manifold Absolute Pressure Sensor Circuit CIRCUIT DESCRIPTION By a built–in sensor unit, the manifold absolute pressure sensor detects the intake manifold absolute pressure as a voltage. The ECM then determines the basic injection dura– tion and basic ignition advance angle based on this voltage. Since the manifold absolute pressure sensor does not use the atmospheric pressure as a criterion, but senses the absolute pressure inside the intake man– ifold (the pressure in proportion to the preset abso– lute vacuum O), it is not influenced by fluctuations in the atmospheric, pressure due to high altitude and other factors. This permits it to control the air– fuel ratio at the proper level under all conditions. DTC No. Diagnostic Trouble Code Detecting Condition Trouble Area • Open or short in manifold absolute pressure Open or short in manifold absolute pressure sensor circuit for 0.5 sec. or more. sensor circuit. • Manifold absolute pressure sensor. • ECM If the ECM detect diagnostic trouble code “31 “, it operates the fail safe function, keeping the ignition timing and fuel injection volume constant and making it possible to drive the vehicle. EG1–373 5S–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check voltage of terminal VC. Check and replace ECM. Check voltage of terminal PIM. When diagnostic trouble code 31 is displayed, check and replace ECM. Check for open and short in harness and connector between manifold absolute pressure sensor and ECM. Repair or replace harness or connector. Check and replace manifold absolute pressure sensor. WIRINGDIA DIAGRAM RAM EG1–374 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals VC and E2 of engine control module connector. (1) Remove glove compartment. (See page EG1–234). (2) Turn ignition switch on. Measure voltage between terminals VC and E2 of engine control module connector. Voltage: 4.5 ∼ 5.5 V Check and replace engine control module. EG1–375 5S–FE ENGINE – CIRCUIT INSPECTION Check voltage between terminals PIM and E2 of engine control module connector. Turn ignition switch on Measure voltage between terminals PI M and E2 of engine control module connector. Voltage: 13 – 3.9 V When diagnostic trouble code 31 is displayed, check and replace engine control module. Check for open and short in harness and connector between engine control module and manifold absolute pressure sensor (See page IN–31). Repair or replace harness or connector. Check and replace manifold absolute pressure sensor. EG1–376 5S–FE ENGINE – CIRCUIT INSPECTION DTC 41 Throttle Position Sensor Circuit CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throttle valve is fully closed, the I D L contacts in the throttle position sensor are on, so the voltage at the ter– minal I D L of the ECM become 0 V. At this time, a voltage of approximately 0.7 V is applied to the terminal VTA of the ECM. When the throttle valve is opened, the I D L contacts go off and thus the power source voltage of approximately 12 V in the ECM is applied to the terminal IDL of the ECM. The voltage applied to the terminal VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 3.2 – 4.9 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from the terminals VTA and IDL, and uses them as one of the conditions for deciding the air–fuel ratio cor– rection, power increase correction and fuel–cut control etc. DTC No. Diagnostic Trouble Code Detecting Condition Open or short in throttle position sensor circuit for 0.5 sec. or more. Trouble Area • Open or short in throttle position sensor circuit. • Throttle position sensor. • ECM HINT; • When the connector for the throttle position sensor is disconnected, diagnostic trouble code 41 is not displayed. Diagnostic trouble code 41 is displayed only when there is an open or short in the VTA signal circuit of the throttle position sensor. EG1–377 5S–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART HINT: If diagnostic trouble codes “22” (engine coolant temperature sensor circuit), “24” (intake air temperature sensor circuit),“31” (manifold absolute pressure sensor circuit) and “41” (throttle posi– tion sensor circuit) are output simultaneously, E2 (sensor ground) may be open. Check voltage of throttle position sensor. Check for momentary interruption (See page EG1–309). Check operation for throttle position sensor. Adjust or replace throttle position sensor. Check for open and short in harness and connector between throttle position sensor and ECM. Repair or replace harness or connector. Check and replace ECM. WIRING DIAGRAM EG1–378 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE HINT: If diagnostic trouble code “22” (engine coolant temperature sensor circuit), “24” (intake air temperature sensor circuit), “31” (manifold absolute pressure sensor circuit) and “41 “ (throttle position sensor circuit) are output simultaneously, E2 (sensor ground) may be open. Check voltage between terminals VTA, IDL and E2 of engine control module connector. (1) Remove glove compartment. (See page EG1–234). (2) Disconnect the vacuum hose from the throt– tle body, then apply vacuum to the throttle opener (See page EG1–204). (3) Turn ignition switch ON. Measure voltage between terminals VTA, IDL and E2 of engine control module connector when the throttle valve is opened gradually from the closed condition. Terminal VTA – E2 IDL – E2 Throttle Valve Fully Closed Fully Open The voltage should increase steadily in propor– tion to the throttle valve opening angle. Check for momentary interruption (See page EG1–309). EG1–379 5S–FE ENGINE – CIRCUIT INSPECTION Check throttle position sensor. (1) Disconnect throttle position sensor connector. (2) Disconnect the vacuum hose from the throt– tle body, then apply vacuum to the throttle opener (See page EG1–204). Measure resistance between terminals 3 (VTA), 2 (IDL) and 1 (E2) of throttle position sensor con– nector when the throttle valve is opened gradu– ally from the closed condition. Terminal 3 (VTA) – 1 (E2) 2 (IDL) – 1 (E2) Throttle Valve Fully Closed Fully Open Resistance between terminals 3 (VTA) and 1 (E2) should increase gradually in accordance with the throttle valve opening angle. Adjust or replace throttle position sensor (See page EG1–209). Check for open and short in harness and connector between engine control module and throttle position sensor (See page IN–31). Repair or replace harness or connector. Check and replace engine control module. EG1–380 5S–FE ENGINE – CIRCUIT INSPECTION DTC 42 No.1 Vehicle Speed Sensor Signal Circuit CIRCUIT DESCRIPTION The No.1 vehicle speed sensor outputs a 4–pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. DTC No. Diagnostic Trouble Code Detecting Condition For A/T All conditions below are detected continuously for 8 sec. or more. (a) No.1 Vehicle speed signal: 0 mph (km/h) (b) Engine speed: 3,100 rpm or more (c) Park/Neutral position switch: OFF For M /T All conditions below are detected continuously for 8 sec. or more. (a) No.1 vehicle speed signal: 0 mph (km/h) (b) Engine speed: Between 3,100 rpm and 5,000 rpm (c) Engine coolant temp.: 80
C (176
F) or more (d) Load driving Trouble Area • • • • Open or short in No.1 vehicle speed sensor circuit. No.1 vehicle speed sensor. Combination meter. ECM HINT: In test mode, diagnostic trouble code 42 is output when vehicle speed is 3 mph (5 km/h) or below. • Waveform between terminals SPD and E1 when vehicle speed is approx. 12 mph (20 km/h). HINT: The greater the vehicle speed, the greater the num– ber of No.1 vehicle speed sensor signals produced. EG1–381 5S–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check operation of speedometer. Check speedometer circuit. (See page BE–66). Check voltage of terminal SPD. Check speedometer circuit. (See page BE–66). Check and replace ECM. WIRING DIAGRAM EG1–382 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check operation of speedometer. Drive the vehicle and check if the operation of the speedometer in the combination meter is normal. The No. 1 vehicle speed sensor is operating normally if the speedometer display is normal. Check speedometer circuit. See combination meter troubleshooting on page BE–66. Check voltage between terminal SPD of engine control module connector and body ground. (1) Remove glove compartment. (See page EG1–234). (2) Disconnect cruise control ECU connector. (3) Shift the shift lever to N position or neutral. (4) Jack up a front wheel on one side. (5) Turn ignition switch on. Measure voltage between terminal SPD of engine control module connector and body ground when the wheel is turned slowly. Voltage is generated intermittently. Check speedometer circuit. See combination meter troubleshooting on page BE–66. Check and replace engine control module. EG1–383 5S–FE ENGINE – CIRCUIT INSPECTION DTC 43 Starter Signal Circuit CIRCUIT DESCRIPTION When the engine is cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery positive voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after–start injection control. DTC No. Diagnostic Trouble Code Detecting Condition No starter signal to ECM. Trouble Area • Open or short in starter signal circuit. • Open or short in ignition switch or starter relay circuit. • ECM DIAGNOSTIC CHART HINT: This diagnostic chart is based on the premise that the engine is cranked normally. If the engine is not cranked, proceed to the matrix chart of problem symptoms on page EG1–327, Check for the test mode. Check for open in harness and connector between ECM and relay. Check and replace ECM. WIRING DIAGRAM Proceed to next circuit inspection shown on matrix chart (See page E–G–327). Repair or replace harness or connector. EG1–384 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check output condition of diagnostic trouble code 43. Setting the test mode. (1) Turn ignition switch OFF. (2) Connect terminals TE2 and E1 of DLC2. (3) Turn ignition switch ON. (Don’t start the engine) (4) Connect terminals TE1 and E1 of DLC2. Check if code “43” is output by the malfunction indicator lamp. Code “43” is output. Start the engine. Check if the code “43” disappear. Code “43” is not output. Proceed to next circuit inspection shown on matrix chart (See page EG1–327). Check for open in harness and connector between engine control module and starter relay (See page IN–31). Repair or replace harness or connector. Check and replace engine control module. EG1–385 5S–FE ENGINE – CIRCUIT INSPECTION DTC 52 Knock Sensor Circuit CIRCUIT DESCRIPTION Knock sensor is fitted the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. DTC No. Diagnostic Trouble Code Detecting Condition Open or short in knock sensor circuit with engine speed between 1,200 rpm and 6,000 rpm. Trouble Area • Open or short in knock sensor circuit. • Knock sensor (looseness) • ECM If the ECM detects the above diagnosis conditions, it operates the fail safe function in which the corrective retard angle value is set to the maximum value. DIAGNOSIS TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern. (a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected. Malfunction: Open or Short in Knock Sensor Start engine and warm up. After engine is warmed up, let it idle for 3 min. With the A/C ON, perform quick racing (5,000 rpm) 3 times. (Rapidly depress the accelerator pedal and suddenly release it.) HINT: If a malfunction exists, the malfunction indicator lamp will light up when sudden racing is performed. NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. EG1–386 5S–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check no continuity of knock sensor circuit. Check knock sensor. Replace knock sensor. Check for open and short in harness and connector between knock sensor and ECM. Repair or replace harness or connector. Does malfunction disappear when a good knock sensor is installed? Check and replace ECM. WIRING DIAGRAM YES Replace knock sensor. EG1–387 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check continuity between terminal KNK of engine control module connector and body ground. (1) Remove glove compartment. (See page EG1–234) (2) Disconnect the engine control module con– nector. Measure resistance between terminal KNK of engine control module connector and body ground. Resistance: 1 M
or higher Go to step EG1–388 5S–FE ENGINE – CIRCUIT INSPECTION Check knock sensor. Disconnect knock sensor connector. Measure resistance between the knock sensor terminal and body. Resistance: 1 M
or higher Replace knock sensor (See page EG1–93). Check for open and short in harness and connector between engine control module and knock sensor (See page IN–31). Repair or replace harness or connector. Does malfunction disappear when a good knock sensor is installed? YES Check and replace engine control module. Replace knock sensor (See page EG1–93). EG1–389 5S–FE ENGINE – CIRCUIT INSPECTION Reference INSPECTION USING OSCILLOSCOPE • With the engine racing (4,000 rpm) measure waveform between terminal KN K of engine control module and body ground. HINT: The correct waveform appears as shown in the illustration on the left. • Spread the time on the horizontal axis, and confirm that period of the wave is 132 sec. (Normal mode vibration frequency of knock sensor: 7.6 KHz). HINT: If normal mode vibration frequency is not 7.6 KHz, the sensor is malfunctioning. EG1–390 5S–FE ENGINE – CIRCUIT INSPECTION DTC 71 EGR System Malfunction CIRCUIT DESCRIPTION The EGR system recirculates exhaust gas, which is controlled to the proper quantity to suit the driving conditions, into the intake air mixture to slow down combustion, reduce the combustion temperature and reduces NOx emissions. The amount of EGR is regulated by the EGR vacuum modulator according to the engine load. If even one of the following conditions is fulfilled, the VSV is turned ON by a signal from the ECM. This results in atmospheric air acting on the EGR valve, closing the EGR valve and shutting off the exhaust gas (EGR cut–OFF). Under the following conditions, EGR is cut to maintain driveability. • Engine coolant temp. below 60
C (140
F). • During deceleration (throttle valve closed). • Light engine load (amount of intake air very small). • Engine speed over 4,400 rpm. • Engine racing. DTC No. Diagnostic Trouble Code Detecting Condition EG R gas temp. is 70
C (158
F) or below for 50 sec. under conditions (a) and (b). (2 trip detection logic) * (a) Engine coolant temp.: 80
C (176
F) or more. (b) EGR operation possible (EX. A/T in 3rd speed (5th for M/T), 55 – 60 mph (88 – 96 km/h), Flat road). *: See page EG1–307 . Trouble Area • • • • • Open in EGR gas temp. sensor circuit. Short in VSV circuit for EGR. EGR hose disconnected, valve stuck. Clogged EGR gas passage. ECM EG1–391 5S–FE ENGINE – CIRCUIT INSPECTION CIRCUIT DESCRIPTION (Cont’d) DIAGNOSIS TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern. (a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded. (b) To check that the malfunction is corrected when the repair is completed confirming that diagnostic trouble code is no longer detected. Malfunction: Open in EGR gas temp. sensor circuit Disconnect the EFI fuse (15 A) for 10 sec. or more, with IG switch OFF. Initiate test mode (Connect terminals TE2 and E1 of data link connector, 1 or 2 with IG switch OFF). Start the engine and warm up. After the engine is warmed up, let it idle for 3 min. With the A/C ON and transmission in 5th gear A/T in “D” position), drive at 55 – 60 mph (88 – 96 km/h) for 4 min. or less. HINT: If a malfunction exists, the malfunction indicator lamp will light up during step (4) . NOTICE: If the conditions in this test are not strictly observed, detection of the malfunction will not be possible. EG1–392 5S–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check voltage of VSV for EGR Power source. Check resistance of VSV for EG R. Replace VSV for EG R. Check for open and short in harness and connector between EFI main relay and ECM. Repair or replace harness or connector. Check and replace ECM. Check EGR system (See page EG1–153) . Repair EGR system. Check resistance of EGR gas temp. sensor. Replace EGR gas temp. sensor. Check for open in harness and connector between EGR gas temp. sensor and ECM. Repair or replace harness or connector. Check and replace ECM. WIRING DIAGRAM EG1–393 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminal EGR of engine control module connector and body ground. (1) Remove glove compartment. (See page EG1–234). (2) Warm up engine to normal operating temperature. Measure voltage between terminal EGR of engine control module connector and body ground. Voltage: 9 –14 V Go to step EG1–394 5S–FE ENGINE – CIRCUIT INSPECTION Check resistance between terminals of VSV for EGR. Remove VSV for EGR. (See page EG1–154, 155*). Measure resistance between terminals of VSV for EG R. Resistance: 33 – 39
(Cold) *: Except California specification vehicle. Replace VSV for EGR. Check for open and short in harness and connector between EFI main relay and VSV for EGR, VSV and engine control module. (See page IN–31). Repair or replace harness or connector. Check and replace engine control module. Check EGR system (See page EG1–153). Repair EGR system. EG1–395 5S–FE ENGINE – CIRCUIT INSPECTION Check resistance of EGR gas temp, sensor. Remove EGR gas temp. sensor. Measure resistance between terminals of EG R gas temp. sensor connector. Resistance: 64 – 97 k
at 50
C (122
F) 11 –16 k
at 100
C (212
F) 2 – 4 k
at 150
C (302
F) Replace EGR gas temp. sensor. Check for open in harness and connector between EGR gas temp. sensor and engine control module (See page IN–31). Repair or replace harness or connector. Check and replace engine control module. EG1–396 5S–FE ENGINE – CIRCUIT INSPECTION DTC 51 Switch Condition Signal Circuit CIRCUIT DESCRIPTION Park/Neutral Position Switch Signal* The ECM uses the signals from the park/neutral position switch to determine whether the transmis– sion is in park or neutral, or in some other gear. Air Conditioning Switch Signal The ECM uses the output from the air conditioning switch to determine whether or not the air conditioning is operating so that it can increase the idling speed of the engine if necessary. Throttle Position Sensor IDL Signal The IDL contacts are mounted in the throttle position sensor, and detects the idle condition. DTC No. Diagnostic Trouble Code Detecting Condition (1) 3 sec. or more after engine starts with closed throttle position switch OFF (IDL). (2) * Park/ Neutral position switch OFF. (Shift position in “R”, “D”, “2” or “L” positions). (3) A/C switch ON. Trouble Area • • • • • Throttle position sensor IDL circuit Accelerator pedal and cable Park/Neutral position switch circuit A/C switch circuit ECM *: Only vehicles with A/T. HINT: In this circuit, diagnosis can only be made in the test mode. DIAGNOSTIC CHART WIRING DIAGRAM EG1–397 5S–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART NG (PNP) Proceed to next circuit inspection shown on matrix chart (See page EG1–327). Check resistance of throttle position sensor. NG (A/C) See page EG1–400. NG (IDL) Check for input signal. Adjust or replace throttle position sensor (See page EG1–209). Check and repair harness or connector between sensor and ECM. Check input circuit of A/C. Check and replace A/C amplifier. Check for open and short in harness and connector between A/C amplifier and ECM. Repair or replace harness or connector. Check and replace ECM. EG1–398 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check output condition of diagnostic trouble code 51. Setting the test mode. (1) Turn ignition switch OFF. (2) Connect terminals TE2 and E1 of DLC2. (3) Turn ignition switch ON. (For checking terminal IDL, disconnect the vacuum hose from the throttle body, then apply vacuum to the throttle opener (See page EG1–204).) (For checking terminal A/C, start the engine.) (4) Connect terminals TE1 and E1 of DLC2. Check if code “51” is output by the malfunction indicator lamp. Condition Park/Neutral Position Switch (PNP) Throttle Position Sensor ( IDL) A/C Switch (A/C) P or N position R, D, 2 or L position Code Normal* 51* Accelerator pedal released Normal* Accelerator pedal depressed 51* A/C SW ON A/C SW OFF Normal *: Before the STA signal is input (ST is not ON), diagnostic trouble code 43 is also output. Diagnostic trouble code 42 is output with vehicle speed 3 mph (5 km/h) or below. IDL .... Go to step A/C ... Go to step Proceed to next circuit inspection shown on matrix chart (See page EG1–327). PN P ... Go to page EG1–400. EG1–399 5S–FE ENGINE – CIRCUIT INSPECTION Check resistance of throttle position sensor. (1) Disconnect throttle position sensor connec– tor. (2) Disconnect the vacuum hose from the throt– tle body, then apply vacuum to the throttle opener (See page EG1–204). Measure resistance between terminals 2 (IDL) and 1(E2) of throttle position sensor connector. Resistance Throttle Valve Fully closed Opened Less than 2.3 k
1 M
or higher Adjust or replace throttle position sensor (See page EG1–209). Check and repair harness or connector between engine control module and throttle position sensor. Disconnect A/C amplifier connector, check voltage between terminal AC2 of A/C amplifier connector and body ground. (1) Remove glove compartment (See page BO–114). (2) Disconnect A/C amplifier connector. (3) Turn ignition switch on. Measure voltage between terminal AC2 of A/C amplifier connector and body ground. Voltage: 9 –14 V Check and replace A/C amplifier. Check for open and short in harness and connector between engine control module and A/C amplifier (See page IN–31). Repair or replace harness or connector. Check and replace engine control module. EG1–400 5S–FE ENGINE – FE ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION Park Neutral Position Switch Circuit (Only vehicles with A–T) CIRCUIT DESCRIPTION The Park/Neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on the terminal NSW of the ECM is grounded to body ground via the starter relay and theft deterrent ECU, thus the terminal NSW voltage becomes 0V. When the shift lever is in the D, 2, L or R position, the Park/Neutral position switch goes off, so the voltage of ECM terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air–fuel ratio correction and for idle speed control (estimated control), etc. When the Park/Neutral position switch is off, code “51” is output in the test mode diagnosis. (This is not abnormal.) DIAGNOSTIC CHART HINT: This diagnosis chart is based on premise that the engine is cranked normally. If the engine is not cranked, proceed to the matrix chart of problem symptoms on page EG1–327. Check for open in harness and connector between park/neutral position switch and ECM. N G Type ΙΙ Proceed to next circuit inspection shown on matrix chart (See age EG1–327). NGType Ι Check output condition of diagnostic trouble code 51. Check and replace ECM. Repair or replace harness or connector. Check park/neutral position switch. (See page AX1–92) Check and replace ECM. Replace park/neutral position switch. EG1–401 5S–FE ENGINE WIRING DIAGRAM – CIRCUIT INSPECTION EG1–402 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check output condition of diagnostic trouble code 51. (1) Connect terminals TE2 and E1 of DLC2. (2) Turn ignition switch on. (3) Crank the engine. (4) Connect terminals TE1 and E1 of DLC2. Check if diagnostic trouble code “51” is output when the shift lever is in the P and D shift positions. Result Shift Position N G Type Ι NG Type ΙΙ “P” Normal Code Code 51 Normal Code ”D” Code 51 Code 51 Normal Code NG Type Ι Go to step NG Type ΙΙ Go to step Proceed to next circuit inspection shown on matrix chart (See age EG1–327). Check for open in harness and connector between engine control module and park/neutral position switch (See page IN–31). Check and replace engine control module. Repair or replace harness or connector. Check park/neutral position switch (See page AX1–92). Replace park/neutral position switch. Check and replace engine control module. EG1–403 5S–FE ENGINE – CIRCUIT INSPECTION ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned on, battery positive voltage is applied to the coil, closing the contacts of the EFI main relay and supplying power to the terminals + B and + 131 of the ECM. DIAGNOSTIC CHART Check voltage of ECM power source. Proceed to next circuit inspection shown on matrix chart (See page EG1–327). Check continuity between terminal E1 and body ground. Repair or replace harness or connector. Check EFI main relay. Replace EFI main relay. Check IGN fuse. Check for short in all the harness and components connected to IGN fuse. Check ignition switch. Replace ignition switch. Check for open in harness and connector between IG switch and EFI main relay, EFI main relay and body ground. Repair or replace harness or connector. Check EFI fuse. Check for open in harness and connector between EFI main relay and battery, EFI main relay and ECM. Check for short in all the harness and components connected to EFI fuse. EG1–404 5S–FE ENGINE WIRING DIAGRAM – CIRCUIT INSPECTION EG1–405 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals + B, + 131 and E1 of engine control module connector. (1) Remove glove compartment. (See page EG1–234) (2) Turn ignition switch ON. Measure voltage between terminals + B, + 131 and E1 of engine control module connector. Voltage: 9 –14 V Proceed to next circuit inspection shown on matrix chart (See page EG1–327). Check for open in harness and connector between terminal E1 of engine control module and body ground (See page IN–31). Repair or replace harness or connector. EG1–406 5S–FE ENGINE – CIRCUIT INSPECTION Check EFI main relay. Remove EFI main relay from J/B No–2. Check continuity between terminals of EFI main relay shown below. Terminals 3 and 5 Open Terminals 1 and 2 Continuity (Reference value 72
) (1) Apply battery voltage between terminals 1 and 2. (2) Check continuity between terminals 3 and 5. Terminals 3 and 5 Continuity Replace EFI main relay. Check IGN fuse. Remove IGN fuse from J/B No.1. Check continuity of IGN fuse. Continuity Check for short in all the harness and components connected to IGN fuse (See attached wiring diagram). EG1–407 5S–FE ENGINE – CIRCUIT INSPECTION Check ignition switch. Remove under cover and finish panel. Check continuity between terminals. continuity Terminal Switch position 10 3 6 7 9 2 4 lG1 ACC AM1 ST2 ST1 IG2 AM2 LOCK ACC START Replace ignition switch. Check for open in harness and connector between IG switch and EFI main relay, EFI main relay and body ground (See page IN–31). Repair or replace harness or connector. Check EFI fuse. Remove EFI fuse from J/B No.2. Check continuity of EFI fuse. Continuity Check for short in all the harness and components connected to EFI fuse (See attached wiring diagram). Check for open in harness and connector between EFI main relay and battery, EFI main relay and engine control module. EG1–408 5S–FE ENGINE – CIRCUIT INSPECTION Back Up Power Source Circuit CIRCUIT DESCRIPTION Battery positive voltage is supplied to terminal BATT of the ECM even when the ignition switch is off for use by the diagnostic trouble code memory and air–fuel ratio adaptive control value memory, etc. DIAGNOSTIC CHART Check EFI fuse. Check for short in all the harness and components connected to EFI fuse. Check voltage of terminal6ATT. Check and repair harness or connector between battery, EFI fuse and ECU. Check operation for the back up. Check and replace ECM. Proceed to next circuit inspection shown on matrix chart (See page EG1–327). WIRING DIAGRAM EG1–409 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check EFI fuse. Remove EFI fuse from J/B No.2. Check continuity of EFI fuse. Continuity Check for short in all the harness and components connected to EFI fuse (See attached wiring diagram). Check voltage between terminal BATT of engine control module connector and body ground. Remove glove compartment. (See page EG1–234) Measure voltage between terminal BATT of en– gine control module connector and body ground. Voltage: 9 –14 V Others Check and repair harness or connector between engine control module and EN fuse, EFI fuse and battery. Are the diagnostic trouble codes still in the memory when the ignition switch is turned OFF? YES Proceed to next circuit inspection shown on matrix chart (See page EG1–327). Check and replace engine control module. EG1–410 5S–FE ENGINE – CIRCUIT INSPECTION Injector Circuit CIRCUIT DESCRIPTION The injectors are provided to the intake manifold. They inject fuel into the cylinders based on the signals from the engine control module. Reference INSPECTION USING OSCILLOSCOPE INJECTOR SIGNAL WAVEFORM • With the engine idling measure waveform between terminals #10, #20 (#1, #2, #3 and #4*) and E01 of engine control module. HINT: The correct waveform appears as shown in the illustration on the below. DIAGNOSTIC CHART Check voltage of terminals #10 and #20 (#1. #2. #3 and #4*). Check AM2 fuse. Check for short in all the harness and components connected to AM2 fuse. Check for open in harness and connector between ECM and battery. Check continuity between terminals E01, E02 and body ground. Repair or replace harness or connector. Check operation for injectors. Replace injector. Check and replace ECM. *: Only for California specification vehicles. EG1–411 5S–FE ENGINE WIRING DIAGRAM Except California specification vehicles. Only for California specification vehicles. – CIRCUIT INSPECTION EG1–412 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals #10, #20 (#1, #2, #3 and #4) of engine control module connector and body ground. (1) Remove glove compartment. (See page EG1–234) (2) Turn ignition switch ON. Exc. California spec. Measure voltage between terminals #10, #20 of engine control module connector and body ground. Only for California spec, Measure voltage between terminals #1, #2, #3 and #4 of engine control module connector and body ground. Voltage: 9 –14 V Go to step EG1–413 5S–FE ENGINE – CIRCUIT INSPECTION Check AM2 fuse. Remove AM2 fuse from J/B No. 2. Check continuity of AM2 fuse. Continuity Check for short in all the harness and components connected to AM2 fuse. Check for open in harness and connector between engine control module and battery. Check for open in harness and connector between terminals E01, E02 of engine control module connector– and body ground (See page IN–31). Repair or replace harness or connector. EG1–414 5S–FE ENGINE – CIRCUIT INSPECTION Check injectors. Disconnect injector connector (See page EG1–189) . Measure resistance of injector. Resistance: Approx. 13.8
at 20C (68F) Check injection volume of injector (See page EG1–195). • Injection volume 49 – 59 cm
(3.0 – 3.6 cu in.)/15 sec. Difference between each injector: Less than 5 cm3 (0.3 cu in.) • Leakage Fuel drop: One drop or less per minute. Replace injector. Check and replace engine control module. EG1–415 5S–FE ENGINE – CIRCUIT INSPECTION IAC Valve Circuit CIRCUIT DESCRIPTION The rotary solenoid type IAC valve is provided on the intake air chamber and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypas– sing the throttle valve is regulated, con– trolling the engine speed. The ECM operated only the IAC valve to perform idle–up and provide feedback for the target idling speed, a VSV for idle–up control is also added (for air condition– ing). DIAGNOSTIC CHART Check voltage terminals ISCO, ISCC. Check and replace ECM. Check operation of the IAC valve. Replace IAC valve. Check for open and short in harness and connector between J/B No.2 and IAC valve, IAC valve and ECM. Repair or replace harness or connector. Check for ECM power source circuit. EG1–416 5S–FE ENGINE WIRING DIAGRAM – CIRCUIT INSPECTION EG1–417 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals ISCO, ISCC of engine control module connector and body ground. (1) Remove glove compartment (See page EG1–234), (2) Disconnect the engine control module con– nectors. (3) Turn ignition switch ON. Measure voltage between terminals ISCO, ISCC of engine control module connector and body ground. Voltage: 9 –14 V Check and replace engine control module. EG1–418 5S–FE ENGINE – CIRCUIT INSPECTION Check operation of the IAC valve. (1) Disconnect IAC valve connector. (2) Remove IAC valve (See page EG1–213). (1) Connect the positive (+) lead from the bat– tery to terminal 2 (+ B) and negative (–) lead to terminal 3 (ISCC), and check that the valve is closed. (2) Connect the. positive (+) lead from the bat– tery to terminal 2 (+ B) and negative (–) lead to terminal 1 (ISCO), and check that the valve is open. (1) The valve is closed. (2) The valve is open. Replace IAC valve. Check for open and short in harness and connector between J/B No.2 and IAC valve, IAC valve and engine control module (See page IN–31). Repair or replace harness or connector. Check for ECM power source circuit (See page EG1–403). EG1–419 5S–FE ENGINE – CIRCUIT INSPECTION Fuel System Circuit CIRCUIT DESCRIPTION Fuel pump control The fuel pump is switched on (low voltage at terminal FC) when STA is on or while the NE signal is input to the ECM. In the diagram below, when the engine is cranked, current flows from terminal ST of the ignition switch to the starter relay coil, the starter relay switches on and current flows to coil L1 of the circuit opening relay. Thus the circuit opening relay switches on, power is supplied to the fuel pump and the fuel pump operates. When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil L2 of the circuit opening relay, the relay switches on and the fuel pump operates. While the NE signal is generated (engine running), the ECM keeps Tr ON (circuit opening relay ON) and the fuel pump also keeps operating. EG1–420 5S–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check voltage terminal FC. Check and replace ECM. Check for ECM power source circuit. Repair or replace. Check for circuit opening relay. Replace circuit opening relay. Check for open in harness and connector between EFI main relay and circuit opening relay and ECM. Repair or replace harness or connector. Check fuel pump. Replace fuel pump. Check for open in harness and connector between circuit opening relay and fuel pump and body ground. EG1–421 5S–FE ENGINE WIRING DIAGRAM – CIRCUIT INSPECTION EG1–422 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals FC of engine control module connector and body ground. (1) Remove glove compartment. (See page EG1–234). (2) Turn ignition switch ON. Measure voltage between terminal FC of engine control module connector and body ground. Voltage: 9 –14 V Check and replace engine control module. Check for ECM power source circuit (See page EG1–403). Repair or replace. EG1–423 5S–FE ENGINE – CIRCUIT INSPECTION Check circuit opening relay. (1) Remove glove compartment (See page EG1–217). (2) Remove circuit opening relay from R/B No.6. Check continuity between terminals of circuit opening relay shown below. Terminals 1 and 2 Open Terminals 2 and 4 Continuity Terminals 3 and 6 Continuity (1) Apply battery voltage between terminals 3 and 6. (2) Check continuity between terminals 1 and 2. Terminals 1 and 2 Continuity Replace circuit opening relay. Check for open in harness and connector between EFI main relay and circuit opening relay, circuit opening relay and engine control module (See page IN–31). Repair or replace harness or connector. Check fuel pump (See page EG1–177). Replace fuel pump. Check for open in harness and connector between circuit opening relay and fuel pump, fuel pump and body ground. EG1–424 5S–FE ENGINE – CIRCUIT INSPECTION VSV Circuit for Fuel Pressure Control (Only for California spec.) CIRCUIT DESCRIPTION The ECM turns on a VSV (Vacuum Switching Valve) to draw the air into the diaphragm chamber of the pressure regulator if it detects that the temperature of the engine coolant is too high during engine starting. The air drawn into the chamber increases the fuel pressure to prevent fuel vapor lock at high engine temperature in order to help the engine start when it is warm. Fuel pressure control ends approx. 90 secs. after the engine is started. DIAGNOSTIC CHART Check VSV for fuel pressure control. Replace VSV. Check voltage of VSV power source. Proceed to next circuit inspection shown on matrix chart (See page EG1–327). Check for open and short in harness and connector between EFI main relay and ECM. Repair or replace harness or connector. Check and replace ECM. EG1–425 5S–FE ENGINE WIRING DIAGRAM – CIRCUIT INSPECTION EG1–426 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check VSV for fuel pressure control. (1) Disconnect VSV connector. (2) Remove VSV. (1) Measure resistance between terminals. (2) Measure resistance between each terminal and the body. (1) Resistance: 33 – 39
at 20
C (68
F) (2) Resistance: 1 M
or higher. Check operation of VSV when battery positive voltage is applied and released to the VSV termi– nals. Battery positive voltage is applied: The air from port E is flowing out through the air filter. Battery positive voltage is not applied: The air from port E is flowing out through port G. Replace VSV for fuel pressure control VSV. G o to step EG1–427 5S–FE ENGINE – CIRCUIT INSPECTION Check voltage between terminal FPU of engine control module connector and body ground. (1) Remove glove compartment (See page EG1–234). (2) Turn ignition switch ON. Measure voltage between terminal FPU of engine control module connector and body ground. Voltage: 9 –14 V Proceed to next circuit inspection shown on matrix chart (See page EG1–327). Check for open and short in harness and connector between engine control module and VSV, VSV and EFI main relay (See page IN–31). Repair or replace harness or connector. Check and replace engine control module. EG1–428 5S–FE ENGINE – CIRCUIT INSPECTION Air Conditioning Cut Control Circuit CIRCUIT DESCRIPTION This circuit cuts air conditioning operation during vehicle acceleration in order to increase accelera– tion performance. During acceleration with the vehicle speed at 16 mph (25 km/h) or less, engine speed at 1,200 rpm or less and throttle valve opening angle at 60 or more, the A/C magnet switch is turned OFF for several seconds. DIAGNOSTIC CHART Check voltage terminal ACT. Check and replace ECM. Check for open and short in harness and connector between ECM and A/C amplifier. Repair or replace harness or connector. Check and replace A/C amplifier. WIRING DIAGRAM EG1–429 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminal ACT of engine control module connector and body ground. (1) Remove glove compartment. (See page EG1–234). (2) Turn ignition switch ON. Measure voltage between terminal ACT of engine control module connector and body ground when A/C switch is turned to ON. Voltage: 9 –14 V Check and replace engine control module. Check for open and short in harness and connector between engine control module and A/C amplifier (See page IN–31). Repair or replace harness or connector. Check and replace A/C amplifier. EG1–430 5S–FE ENGINE – CIRCUIT INSPECTION TE1 TE2 Terminal Circuit CIRCUIT DESCRIPTION Terminals TE1 and TE2 are located in the data link connector 1 and 2. The data link connector 1 located in the engine compartment and the data link connector 2 located in the cabin. When these terminals are connected with the E1 terminal, diagnostic trouble codes in normal mode or test mode can be read from the malfunction indicator lamp on the combination meter. DIAGNOSTIC CHART HINT: If terminals TE1 and TE2 are connected with terminal E1, diagnostic trouble code is not output or test mode is not activated. Even though terminal TE1 is not connected with terminal E1, the malfunction indicator lamp blinks. For the above phenomenon, the likely cause is an open or short in the wire harness, or malfunction inside the ECM. Check voltage of terminals TE1, TE2. Check and replace ECM. Check continuity between terminal E1 and body ground. Repair or replace harness or connector. Check for open and short in harness and connector between data link connector 1, 2 and ECM. Repair or replace harness or connector. Check and replace ECM. WIRING DIAGRAM EG1–431 5S–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals TE1, TE2, and E1 of data link connector 1 and 2. Turn ignition switch ON. Measure voltage between terminals TE1, TE2 and E1 of data link connector 1 and 2. Voltage: 9 –14 v Check and replace engine control module. Check continuity between terminal E1 of data link connector 1, 2 and body ground. Repair or replace harness or connector. Check for open and short in harness and connector between engine control module and data link connector 1, 2 (See page IN–31). Repair or replace harness or connector. Check and replace engine control module. EG2–1 1MZ–FE ENGINE – 1MZ–FE ENGINE EG2–2 1MZ–FE ENGINE – ENGINE MECHANICAL ENGINE MECHANICAL DESCRIPTION The 1 MZ–FE engine is a V–6, 3.0 liter 24 valve DOHC engine. OPERATION EG2–3 1MZ–FE ENGINE – ENGINE MECHANICAL The 1 MZ–FE engine has 6 cylinders in a V arrangement at a bank angle of 60
. From the front of the RH bank cylinders are numbered 1–3–5, and from the front of the LH bank cylinders are numbered 2–4–6. The crankshaft is supported by 4 bearings inside the crankcase. These bearings are made of copper and lead alloy. The crankshaft is integrated with 9 semi counterweights for balance. Oil holes are placed in the center of the crankshaft for supply oil to the connecting rods, bearings, pistons and other components. This engine’s firing order is 1–2–3–4–5–6. The cylinder head is made of aluminum alloy, with a cross flow type intake and exhaust layout and with pent–roof type combustion chambers. The spark plugs are located in the center of the combustion chambers. At the front and rear of the intake manifold, a water passage has been provided which connects the RH and LH cylinder heads. Exhaust and intake valves are equipped with irregular pitch springs made of special valve spring carbon steel which are capable of following the cam profile at all engine speeds. The RH and LH exhaust camshafts are driven by a single timing belt, and a gear on the exhaust camshaft engages with a gear on the intake camshaft to drive it. The camshaft journal is supported at 5 places between the valve lifters of each cylinder and on the front end of the cylinder head. Lubrication of the cam journals and gears is accomplished by oil being supplied through the oiler port in the center of the camshaft. Adjustment of the valve clearance is done by means of an outer shim type system, in which valve adjusting shims are located above the valve lifters. This permits replacement of the shims without removal of the camshafts. The timing belt covers consist of the resin type No.2 and No.1 above and below the engine RH mounting bracket. Pistons are made of high temperature–resistant aluminum alloy, and a depression is built into the piston head to prevent interference with the valves. Piston pins are the full–floating type, with the pins fastened to neither the piston boss nor the connecting rods. Instead, snap rings are fitted on both ends of the pins, preventing the pins from falling out. The No.1 compression ring is made of steel and the No.2 compression ring is made of cast iron. The oil ring also is made of a combination of steel and stainless steel. The outer diameter of each piston ring is slightly larger than the diameter of the piston and the flexibility of the rings allows them to hug the cylinder walls when they are mounted on the piston. Compression rings No. 1 and No.2 work to prevent gas leakage from the cylinder and the oil ring works to clear oil off the cylinder walls to prevent it from entering the combustion chambers. The cylinder block is made of aluminum alloy with a bank angle of 60
. It has 6 cylinders which are approximately 1.6 times the length of the piston stroke. The top of the cylinders is closed off by the cylinder heads and the lower end of the cylinders becomes the crankcase, in which the crankshaft is installed. In addition, the cylinder block contains a water jacket, through which coolant is pumped to cool the cylinders. The No. 1 and No.2 oil pans are bolted onto the bottom of the cylinder block. The No. 1 oil pan is made of aluminum alloy. The No.2 oil pan is an oil reservoir made of pressed sheet steel. An oil pan baffle plate keeps sufficient oil in the bottom of the No.2 oil pan even when the vehicle is tilted. This dividing plate also prevents the oil from sloshing when the vehicle is stopped suddenly and the oil shifts away from the oil pump suction pipe. Plastic region tightening bolts are used for the cylinder head, main bearing caps and connecting rods. EG2–4 1MZ–FE ENGINE – ENGINE MECHANICAL PREPARATION SST (SPECIAL SERVICE TOOLS) 09201–01055 Valve Guide Bushing Remover & Replacer 5.5 09201–41020 Valve Stem Oil Seal Replacer 09202–70010 Valve Spring Compressor 09213–54015 Crankshaft Pulley Holding Tool 09213–60017 Crankshaft Pulley & Gear Puller Set (09213–00020) Body With Bolt (09213–00030) Handle (09213–00050) Bolt set Crankshaft timing pulley (09213–00060) Bolt set Crankshaft pulley 08223–00010 Cover & Seal Replacer Crankshaft front oil seal 09223–15030 Oil Seal & Bearing Replacer 09223–46011 Crankshaft Front Oil Seal Replacer 09248–55040 Valve Clearance Adjust Tool set Crankshaft rear oil seal Crankshaft timing pulley EG2–5 1MZ–FE ENGINE – ENGINE MECHANICAL (09248 –05410) Valve Lifter Press (09248–05420) Valve Lifter Stopper 09249–63010 Torque Wrench Adaptor 09330–00021 Companion Flange Holding Tool RH camshaft timing pulley Crankshaft pulley 09608–20012 Front Hub & Drive Pinion Bearing Tool Set (09608–03020) Handle (09608–03070) Replacer Crankshaft rear oil seal Valve guide bushing Spark plug tube gasket 09631–22020 Power Steering Hose Nut 14 x 17 mm Wrench Set 09816–30010 Oil Pressure Switch Socket Knock sensor Oil pressure switch 09843–18020 Diagnosis Check Wire 09960–10010 Variable Pin Wrench Set (09962–01000) Variable Pin Wrench Arm Assy Camshaft timing pulley EG2–6 1MZ–FE ENGINE – FE ENGINE – ENGINE MECHANICAL RECOMMENDED TOOLS 09040–00010 Hexagon Wrench Set 09090–04010 Engine Sling Device For suspending engine 09200–00010 Engine Adjust Kit 09258–00030 Hose Plug set 09904–00010 Expander Set EQUIPMENT Battery specific gravity gauge Caliper gauge CO/HC meter Connecting rod aligner Cylinder gauge Dial indicator Dye penetrant Engine tune–up tester Heater Micrometer Piston ring compressor Piston ring expander Plastigage Precision straight edge Magnetic finger Plug for the vacuum hose, fuel hose etc. EG2–7 1MZ–FE ENGINE – ENGINE MECHANICAL Soft brush Spring tester Valve spring Steel square Valve spring Thermometer Torque wrench Valve seat cutter Vernier calipers COOLANT Item Classification Capacity Ethylene–glycol base 8.7 liters (9.2 US qts, 7.7 Imp. qts) Engine coolant LUBRICANT Item Engine oil Dry fill Drain and refill w/ Oil filter change w/o Oil filter change Capacity Classification 5.5 liters (5.8 US qts, 4.8 Imp. qts) API grade SG or SH, Energy–Conserving II or ILSC multigrade and recommended viscosity oil with SAE 5W–30 being the preferred engine oil 4.7 liters (5.0 US qts, 4.1 Imp. qts) 4.5 liters (4.8 US qts, 4.0 Imp. qts) SSM (SERVICE SPECIAL MATERIALS) 08826–00080 Seal packing or equivalent Camshaft bearing cap Semi–circular plug Spark plug tube Cylinder head cover 08826–00080 Seal packing or equivalent Intake air control valve Rear oil seal retainer No. 1 oil pan No.2 oil pan 08826–00100 Seal Packing 1282B, THREE BOND 1282B or equivalent Engine coolant drain cock Water seal plate Water inlet housing 08833–00070 Adhesive 1311, THREE BOND 1311 or equivalent Drive plate bolt TVV 08833–00080 Adhesive 1344, THREE BOND 1344, LOCTITE 242 or equivalent Oil pressure switch EG2–8 1MZ–FE ENGINE – ENGINE MECHANICAL TUNE–UP ENGINE COOLANT INSPECTION 1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The engine coolant level should be between the ”LOW” and ”FULL” lines. If low, check for leaks and add engine coolant up to the ”FULL” line. 2. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap from the water outlet. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) There should not be any excessive deposits of rust or scale around the radiator cap or water outlet filler hole, and the coolant should be free from oil. If excessively dirty, clean the coolant passages and replace the coolant. Capacity: 8.7 liters (9.2 US qts, 7.7 Imp. qts) HINT: • Use a good brand of ethylene–glycol base cool– ant and mix it according to the manufacturer’s directions. • Using coolant which includes more than 50 % ethylene–glycol (but not more than 70 %) is recommended. NOTICE: • Do not use an alcohol type coolant. • The coolant should be mixed with demineralized water or distilled water. (c) Reinstall the radiator cap. EG2–9 1MZ–FE ENGINE – ENGINE MECHANICAL ENGINE OIL INSPECTION 1. CHECK OIL QUALITY Check the oil for deterioration, entry of water, dis– coloring or thinning. If oil quality is visibly poor, replace the oil. Oil grade: API grade SG or SH, Energy – Conserving H or ILSAC multigrade engine oil. Recommended viscosi– ty is as shown in the illustration, with SAE 5W–30 being the preferred engine oil. Drain and refill capacity: w/ Oil filter change 4.7 liters (5.0 US qts, 4.1 Imp, qts) w/o Oil filter change 4.5 liters (4.8 US qts, 4.0 Imp. qts) 2. CHECK ENGINE OIL LEVEL The oil level should be between the ”L” and ”F” marks on the dipstick. If low, check for leakage and add oil up to the ”F” mark. NOTICE: • Do not fill with engine oil above the ’F’ mark. • Install the oil dipstick facing the direction shown in the illustration. EG2–10 1MZ–FE ENGINE – ENGINE MECHANICAL BATTERY INSPECTION 1. Except Delco Battery: CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. A. Maintenance Free Battery If under the lower level, replace the battery (or add distilled water if possible). Check the charging system. B. Except Maintenance Free Battery If under the ”LOWER” or ”MIN’ line, add distilled water. 2. Except Delco Battery: CHECK BATTERY VOLTAGE AND SPECIFIC GRAVITY A. Maintenance Free Battery Measure the battery voltage between the terminals negative (–) and positive (+) of the battery. Standard voltage: 12.7 – 12.9 V at 20°C (68°F) HINT: • Before measuring the voltage, turn the ignition switch to LOCK and turn off the electrical sys– tems (headlight, blower motor, rear defogger etc.; for 60 seconds to remove the surface charge. • If the vehicle has been running, wait 5 minutes or more after the vehicle stops before measuring the battery voltage. If the voltage is less than specification, charge the battery. HINT: Check the indicator as shown in the illustration. EG2–11 1MZ–FE ENGINE – ENGINE MECHANICAL B. Except Maintenance Free Battery Check the specific gravity of each cell. Standard specific gravity: 55D23L battery for GNB Incorporated 1.25 – 1.27 at 20°C (60°F) 5513231– battery for JOHNSON CONTROLS 1.26 – 1.28 at 27°C (81°F) 80D26L battery for GNB Incorporated 1.27 – 1.29 at 20°C (68°F) 80D26L battery for JOHNSON CONTROLS 1.28 – 1.30 at 27°C (80°F) If the gravity is less than specification, charge the battery. HINT: Check the indicator as shown in the illustration. 3. Delco Battery: CHECK HYDROMETER Green Dot visible: Battery is adequately charged Dark (Green Dot not visible): Battery must be charged Clear or Light Yellow: Replace battery HINT: There is no need to add water during the entire service life of the battery. 4. CHECK BATTERY TERMINALS, FUSIBLE LINK AND FUSES (a) Check that the battery terminals are not loose or corroded. (b) Check the fusible link and fuses for continuity. AIR FILTER INSPECTION AND CLEANING 1. REMOVE AIR FILTER EG2–12 1MZ–FE ENGINE – ENGINE MECHANICAL 2. INSPECT AND CLEAN AIR FILTER (a) Visually check that the air filter is not excessively dirty, damaged or oily. If necessary, replace the air filter. (b) Clean the air filter with compressed air. First blow from the inside thoroughly, then blow from the outside of the air filter. 3. REINSTALL AIR FILTER GENERATOR DRIVE BELT INSPECTION INSPECT DRIVE BELT (a) Visually check the belt for excessive wear, frayed cords etc. If necessary, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced. (b) Using a belt tension gauge, measure the drive belt tension. Belt tension gauge: Nippondenso BTG – 20 (95506–00020) Borroughs No. BT–33–73F Drive belt tension: New belt 175 ± 5 lbf Used belt 115 ±20 lbf If the belt tension is not as specified, adjust it. HINT: • ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. • ”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. • After installing the belt, check that it fits properly in the ribbed grooves. • Check by hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. • After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. EG2–13 1MZ–FE ENGINE – ENGINE MECHANICAL VALVE CLEARANCE INSPECTION AND ADJUSTMENT HINT: Inspect and adjust the valve clearance when the engine is cold. 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. DRAIN ENGINE COOLANT 3. DISCONNECT RADIATOR INLET HOSE 4. DISCONNECT ACCELERATOR CABLE 5. DISCONNECT THROTTLE CABLE 6. REMOVE AIR CLEANER CAP, VOLUME AIR FLOW METER AND AIR CLEANER HOSE (a) Disconnect the volume air flow meter connector and wire clamp. (b) Disconnect the accelerator cable clamp. (c) Disconnect the PCV hose. (d) Loosen the air cleaner hose clamp bolt. (e) Disconnect the 4 air cleaner cap clips. (f) Remove the air cleaner cap and volume air flow meter together with the air cleaner hose. 7. REMOVE V–BANK COVER Using a 5 mm hexagon wrench, remove the 2 nuts and V–bank cover. EG2–14 1MZ–FE ENGINE – ENGINE MECHANICAL 8. REMOVE EMISSION CONTROL VALVE SET (a) Disconnect the following vacuum hoses: (1) Vacuum hose from fuel pressure control VSV (2) Vacuum hose from fuel pressure regulator (3) Vacuum hose from cylinder head rear plate (4) Vacuum hose from intake air control valve VSV (5) Vacuum hose from EGR vacuum modulator (6) Vacuum hose from EGR valve (b) Disconnect the following connectors: (1) Intake air control valve connector (2) Fuel pressure connector (3) EGR VSV connector (c) Remove the 2 nuts and emission control valve set. 9. REMOVE AIR INTAKE CHAMBER (a) Disconnect the following hoses: (1) Brake booster vacuum hose (2) PCV hose (3) Intake air control valve vacuum hose (b) Disconnect the data link connector 1. (c) Remove the nut and disconnect the 2 ground straps. EG2–15 1MZ–FE ENGINE – ENGINE MECHANICAL (d) Remove the bolt and disconnect the hydraulic motor pressure hose from the air intake chamber. (e) Remove the bolt, and disconnect the ground strap. (f) Disconnect the RH oxygen sensor connector clamp from the PS pressure tube. (g) Remove the 2 nuts, and disconnect the PS pressure tube. (h) Disconnect the 2 PS air hoses. (i) Remove the 2 bolts and No.1 engine hanger. (j) Remove the 2 bolts and air intake chamber stay. (k) Remove the 4 nuts, EGR pipe and 2 gaskets. EG2–16 1MZ–FE ENGINE – FE ENGINE – ENGINE MECHANICAL (I) Disconnect the following connectors: (1) Throttle position sensor connector (2) IAC valve connector (3) EGR gas temperature sensor connector (4) A/C idle–up connector (m) Disconnect the following vacuum hoses: (1) 2 vacuum hoses from TVV (2) Vacuum hose from cylinder head rear plate (3) Vacuum hose from charcoal canister (n) Disconnect the following hoses: (1) 2 water bypass hoses (2) Air assist hose (o) Using an 8 mm hexagon wrench, remove the 2 bolts, 2 nuts, air intake chamber and gasket. EG2–17 1MZ–FE ENGINE – ENGINE MECHANICAL 10. DISCONNECT ENGINE WIRE FROM ENGINE LH SIDE (a) Disconnect the following connectors: (1) 3 injector connectors (2) 3 ignition coil connectors (b) Remove the 2 nuts, and disconnect the engine wire. 11. DISCONNECT ENGINE WIRE FROM NO.3 TIMING BELT COVER Remove the bolt and 3 clamps, and disconnect the engine wire. 12. DISCONNECT ENGINE WIRE FROM ENGINE REAR SIDE Remove the 2 nuts, and disconnect the engine wire. 13. DISCONNECT ENGINE WIRE FROM ENGINE RH SIDE (a) Disconnect the following connectors: (1) 3 injector connectors (2) 3 ignition coil connectors (b) Remove the 5 nuts, and disconnect the engine wire. EG2–18 1MZ–FE ENGINE – ENGINE MECHANICAL 14. REMOVE IGNITION COILS Remove the 6 bolts and 6 ignition coils from the RH and LH cylinder heads. HINT: Arrange the ignition coils in the correct order. 15. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the 6 spark plugs from the RH and LH cylinder heads. 16. REMOVE CYLINDER HEAD COVERS Remove the 8 bolts, cylinder head cover and gasket. Remove the 2 cylinder head covers. 17. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Turn the crankshaft pulley, and align its groove with the timing mark ”0” of the No.1 timing belt cover. (b) Check that the valve lifters on the No.1 (IN) are loose and valve lifters on the No.1 (EX) are tight. If not, turn the crankshaft 1 revolution (360°) and align the mark as above. EG2–19 1MZ–FE ENGINE – ENGINE MECHANICAL 18. INSPECT VALVE CLEARANCE (a) Check only those valves indicated in the illustration. • Using a feeler gauge, measure the clearance be– tween the valve lifter and camshaft. • Record out of specification valve clearance mea– surements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake 0.15 – 0.25 mm (0.006 – 0.010 in.) Exhaust 0.25 – 0.35 mm (0.010 – 0.014 in.) (b) Turn the crankshaft 2/3 of a revolution (240
), and check only. the valves indicated in the illustration. Measure the valve clearance. (See procedure step (a)) EG2–20 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Turn the crankshaft a further 2/3 of a revolution (240
), and check only the valves indicated in the illustration. Measure the valve clearance. (See procedure step (a)) 19. ADJUST VALVE CLEARANCE (a) Remove the adjusting shim. • Turn the camshaft so that the cam lobe for the valve to be adjusted faces up. • Turn the valve lifter with a screwdriver so that the notches would be perpendicular to the cam– shaft. • Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A). SST 09248–55040 (09248–05410, 09248–05420) HINT: • Apply SST (B) at a slight angle on the side marked with ”9” or ”7”, at the position shown in the illustration. • When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle. EG2–21 1MZ–FE ENGINE – ENGINE MECHANICAL • Using a small screwdriver and a magnetic finger, remove the adjusting shim. (b) Determine the replacement adjusting shim size ac– cording to the following Formula or Charts on the next 2 pages: • Using a micrometer, measure the thickness of the removed shim. • Calculate the thickness of a new shim so the valve clearance comes within specified value. T .......... Thickness of used shim A .......... Measured valve clearance N .......... Thickness of new shim Intake N = T + (A – 0.20 mm (0.008 in.)) Exhaust N = T + (A – 0.30 mm (0.012 in.)) • Select a new shim with a thickness as close as possible to the calculated values. HINT: Shims are available in 17 sizes in increments of 0.050 mm (0.0020 in.), from 2.500 mm (0.0984 in.) to 3.300 mm (0.1299 in.). (c) Install a new adjusting shim. • Place a new adjusting shim on the valve lifter, with imprinted numbers facing down. • Press down the valve lifter with SST (A), and remove SST (B). SST 09248–55040 (09248–05410, 09248–05420) (d) Recheck the valve clearance. EG2–22 Adjusting Shim Selection Chart (Intake) 1MZ–FE ENGINE – ENGINE MECHANICAL Adjusting Shim Selection Chart (Exhaust) 1MZ–FE ENGINE – ENGINE MECHANICAL EG2–23 EG2–24 1MZ–FE ENGINE – ENGINE MECHANICAL 20. REINSTALL CYLINDER HEAD COVERS (a) Apply seal packing to the cylinder heads as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent (b) Install the gasket to the cylinder head cover. (c) Install the cylinder head cover with the 8 bolts. Uni– formly tighten the bolts in several passes. Install the 2 cylinder head covers. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) 21. REINSTALL SPARK PLUGS Using a 16 mm plug wrench, install the 6 spark plugs to the RH and LH cylinder heads. Torque: 18 N–m (180 kgf–cm, 13 ft–lbf) 22. REINSTALL IGNITION COILS Install the6 ignition coils to the RH and LH cylinder heads. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) EG2–25 1MZ–FE ENGINE – ENGINE MECHANICAL 23. RECONNECT ENGINE WIRE TO ENGINE RH SIDE (a) Connect the engine wire with the 5 nuts. (b) Connect the following connectors: (1) 3 injector connectors (2) 3 ignition coil connectors 24. RECONNECT ENGINE WIRE TO ENGINE REAR SIDE Connect the engine wire with the 2 nuts. 25. RECONNECT ENGINE WIRE TO ENGINE LH SIDE (a) Connect the engine wire with the 2 nuts. (b) Connect the following connectors: (1) 3 injector connectors (2) 3 ignition coil connectors 26. RECONNECT ENGINE WIRE TO NO.3 TIMING BELT COVER (a) Connect the 3 clamps. (b) Connect the engine wire with the bolt. EG2–26 1MZ–FE ENGINE – ENGINE MECHANICAL 27. REINSTALL AIR INTAKE CHAMBER (a) Using an 8 mm hexagon wrench, install a new gasket and the air intake chamber with the 2 bolts and 2 nuts. Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) (b) Connect the following hoses: (1) 2 water bypass hoses (2) Air assist hose (c) Connect the following vacuum hoses: (1) 2 vacuum hoses to TVV (2) Vacuum hose to cylinder head rear plate (3) Vacuum hose to charcoal canister (d) Connect the following connectors: (1) Throttle position sensor connector (2) IACV valve connector (3) EGR gas temperature sensor connector (4) A/C idle–up connector EG2–27 1MZ–FE ENGINE – ENGINE MECHANICAL (e) Install 2 new gaskets and EGR pipe with the 4 nuts. Torque: 12 N–m (120 kgf–cm. 9 ft–lbf) (f) install the No. 1 engine hanger with the 2 bolts. Torque: 39 N–m (400 kgf–cm, 19 ft–lbf) (g) Install the air intake chamber stay with the 2 bolts. Torque: 19.5 N–m (200 kgf–cm, 14 ft–lbf) (h) Connect the 2 PS air hoses. (i) Connect the PS pressure tube with the 2 nuts. (j) Connect the RH oxygen sensor connector clamp to the PS pressure tube. (k) Connect the ground strap with the bolt. (1) Connect the hydraulic pressure pipe to the air intake chamber with the bolt. EG2–28 1MZ–FE ENGINE – ENGINE MECHANICAL (m) Connect the following hoses: (1) Brake booster vacuum hose (2) PCV hose (3) Intake air control valve vacuum hose (n) Connect the data link connector 1. (o) Connect the 2 ground straps with the nut. 28. REINSTALL EMISSION CONTROL VALVE SET (a) Install the emission control valve set with the 2 bolts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) (b) Connect the following connectors: (1) Intake control valve connector (2) Fuel pressure connector (3) EGR VSV connector (c) Connect the following vacuum hoses: (1) Vacuum hose to fuel pressure control VSV (2) Vacuum hose to fuel pressure regulator (3) Vacuum hose to cylinder head rear plate (4) Vacuum hose to intake air control valve (5) Vacuum hose to EGR vacuum modulator (6) Vacuum hose to EGR valve 28. REINSTALL V–BANK COVER Using a 5 mm hexagon wrench, install the V– bank cover with the 2 nuts. EG2–29 1MZ–FE ENGINE – ENGINE MECHANICAL 29. REINSTALL AIR CLEANER CAP, VOLUME AIR FLOW METER AND AIR CLEANER HOSE (a) Connect the air cleaner hose, and install the air clean– er cap and volume air flow meter with the 4 clips. (b) Tighten the air cleaner hose clamp bolt. (c) Connect the PCV hose. (d) Connect the accelerator cable clamp. (e) Connect the volume air flow meter connector and wire clamp. 30. RECONNECT THROTTLE CABLE 31. RECONNECT ACCELERATOR CABLE 32. RECONNECT RADIATOR INLET HOSE 33. FILL WITH ENGINE COOLANT Capacity: 8.7 liters (9.2 US qts, 7.7 Imp. qts) 34. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG2–30 1MZ–FE ENGINE – ENGINE MECHANICAL IGNITION TIMING INSPECTION 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. CONNECT TACHOMETER TO ENGINE Connect the tester probe of a tachometer to terminal IG(–) of the data link connector 1. NOTICE: • Never allow the tachometer terminal to touch ground as it could result In damage to the igniter and/or ignition coil. • As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of your unit before use. 3. CONNECT TIMING LIGHT TO ENGINE (a) Using a 5 mm hexagon wrench, remove the 2 cap nuts and V– bank cover. (b) Connect the timing light pickup clip to the the green lead wire for the No.4 ignition coil. HINT: Use a timing light that can detect the primary signal. 4. CHECK IDLE SPEED (a) Race the engine speed at 2,500 rpm for approx. 90 seconds. EG2–31 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Check the idle speed. Idle speed: 700 ± 60 rpm 5. INSPECT IGNITION TIMING (a) Using SST, connect terminals TE1 and E1 of the data link connector 1. SST 09843–18020 (b) Using a timing light, check the ignition timing. Ignition timing: 8 – 12
BTDC @ idle (Transmission in neutral position) If the ignition timing is not as specified, check that following conditions are normal: • Throttle valve fully closed • Continuity between terminals IDL1 and E2 of the throttle position sensor. • Valve timing (c) Remove the SST from the data link connector 1. SST 09843–18020 6. FURTHER CHECK IGNITION TIMING Ignition timing: 7 – 17
BTDC @ idle (Transmission in neutral position) HINT: The timing mark moves in a range between 7
and 17
. EG2–32 1MZ–FE ENGINE – ENGINE MECHANICAL 7. DISCONNECT TIMING LIGHT FROM ENGINE (a) Remove the timing light. (b) Using a 5 mm hexagon wrench, install the V–bank cover with the 2 cap nuts. 8. DISCONNECT TACHOMETER FROM ENGINE EG2–33 1MZ–FE ENGINE – ENGINE MECHANICAL IDLE SPEED INSPECTION 1. INITIAL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) All pipes and hoses of air induction system connected (d) All accessories switched OFF (e) All vacuum lines properly connected HINT: All vacuum hoses for EGR system, etc. should be properly connected. (f) SFI system wiring connectors fully plugged (g) Ignition timing set correctly (h) Transmission, in neutral position 2. CONNECT TACHOMETER Connect the tester probe of a tachometer to terminal IG(–) of the data link connector 1. NOTICE: • Never allow the tachometer terminal to touch ground as it could result in damage to the igniter and/or ignition coil. • As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of your unit before use. 3. INSPECT IDLE SPEED (a) Race the engine speed at 2,500 rpm for approx. 90 seconds. (b) Check the idle speed. Idle speed: 700 ± 50 rpm If the idle speed is not as specified, check the IAC valve and air intake system. 4. DISCONNECT TACHOMETER EG2–34 1MZ–FE ENGINE – ENGINE MECHANICAL IDLE AND OR 2500 RPM CO HC CHECK HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. 1. INITIAL CONDITIONS (a) Engine at normal operating temperature (b) Air cleaner installed (c) All pipes and hoses of air induction system connected (d) All accessories switched OFF (e) All vacuum lines properly connected HINT: All vacuum hoses for EGR systems, etc. should be properly connected. (f) SFI system wiring connectors fully plugged (g) Ignition timing set correctly (h) Transmission in neutral position (i) Tachometer and CO/HC meter calibrated by hand 2. START ENGINE 3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS 4. INSERT CO/NC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING 5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 2,500 RPM HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. EG2–35 1MZ–FE ENGINE – ENGINE MECHANICAL Troubleshooting If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given below. See the table below for possible causes, and then inspect and correct the applicable causes if neces– sary. Phenomenon Causes Normal High Rough idle 1. Faulty ignitions: • Incorrect timing • Fouled, shorted or improperly gapped plugs • Open or crossed high–tension cords • Cracked distributor cap 2. Incorrect valve clearance 3. Leaky EGR valve 4. Leaky intake and exhaust valves 5. Leaky cylinder Low High Rough idle (Fluctuating HC reading) 1. Vacuum leaks: • PCV hose • EGR valve • Intake manifold • Air intake chamber • Throttle body • IAC valve • Brake booster line 2. Lean mixture causing misfire High High Rough idle (Black smoke from exhaust) 1. Restricted air filter 2. Faulty SFI systems: • Faulty fuel pressure regulator • Clogged fuel return line • Defective ECT switch • Faulty ECM • Faulty injector • Faulty throttle position sensor • Faulty volume air flow meter EG2–36 1MZ–FE ENGINE – ENGINE MECHANICAL COMPRESSION CHECK HINT: If there is lack of power, excessive oil consump– tion or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE V–BANK COVER Using a 5 mm hexagon wrench, remove the 2 cap nuts and V– bank cover. 3. REMOVE IGNITION COILS (a) Disconnect the 6 connectors from the RH and LH cylinder heads. (b) Remove the 6 bolts and 6 ignition coils from the RH and LH cylinder heads. HINT: Arrange the ignition coils in the correct order. EG2–37 1MZ–FE ENGINE – ENGINE MECHANICAL 4. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the 6 spark plugs from the RH and LH cylinder heads. 5. CHECK CYLINDER COMPRESSION PRESSURE (a) Insert a compression gauge into the spark plug hole. (b) Fully open the throttle. (c) While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. (d) Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short a time as possible. Compression pressure: 1,226 kPa (12.5 kgf/cm2, 178 psi) or more Minimum pressure: 981 kPa (10.0 kgf/cm2, 142 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less (e) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylin– der through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. • If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. • If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 6. REINSTALL SPARK PLUGS Using a 16 mm plug wrench, install the 6 spark plugs to the RH and LH cylinder heads. Torque: 18 N–m (180 kgf–cm, 13 ft–lbf) EG2–38 1MZ–FE ENGINE – ENGINE MECHANICAL 7. INSTALL IGNITION COILS (a) Install the 6 ignition coil to the RH and LH cylinder heads with the 6 bolts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) (b) Connect the 6 ignition coil connectors. 8. REINSTALL V–BANK COVER Using a 5 mm hexagon wrench, install the V –bank cover with the 2 cap nuts. EG2–39 1MZ–FE ENGINE – ENGINE MECHANICAL TIMING BELT COMPONENTS FOR REMOVAL AND INSTALLATION EG2–40 1MZ–FE ENGINE – ENGINE MECHANICAL EG2–41 1MZ–FE ENGINE – ENGINE MECHANICAL TIMING BELT REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE ENGINE COOLANT RESERVOIR TANK (a) Disconnect the reservoir hose. (b) Using a screwdriver, remove the reservoir tank. 3. REMOVE GENERATOR DRIVE BELT Loosen the pivot bolt and adjusting lock bolt, and remove the drive belt. 4. REMOVE RH FRONT WHEEL 5. REMOVE RH FENDER APRON SEAL EG2–42 1MZ–FE ENGINE – ENGINE MECHANICAL 6. REMOVE PS DRIVE BELT Loosen the 2 bolts, and remove the drive belt. 7. DISCONNECT GROUND STRAPS Disconnect the 2 straps. 8. REMOVE RH ENGINE MOUNTING STAY Remove the 3 bolts and RH engine mounting stay. 9. REMOVE ENGINE MOVING CONTROL ROD AND NO.2 RH ENGINE MOUNTING BRACKET Remove the 3 bolts, control rod and mounting brack– et. 10. REMOVE NO.2 GENERATOR BRACKET (a) Loosen the generator pivot bolt. (b) Remove the nut and bracket. EG2–43 1MZ–FE ENGINE – ENGINE MECHANICAL 11. REMOVE CRANKSHAFT PULLEY (a) Using SST, remove the pulley bolt. SST 09213–54016, 09330–00021 (b) Using SST, remove the pulley. SST 09213–00060 12. REMOVE No.1 TIMING BELT COVER Remove the 4 bolts and timing belt cover. 13. DISCONNECT ENGINE WIRE (a) Remove the bolt holding the engine wire to the No.3 timing belt cover. (b) Disconnect the engine wire from the clamp. 14. REMOVE N0.2 TIMING BELT COVER Remove the 5 bolts and timing belt cover. EG2–44 1MZ–FE ENGINE – ENGINE MECHANICAL 15. REMOVE ENGINE RH MOUNTING BRACKET Remove the 2 bolts, nut and mounting bracket. 16. REMOVE TIMING BELT GUIDE 17. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Temporarily install the crankshaft pulley bolt to the crankshaft. (b) Turn the crankshaft and align the crankshaft timing pulley groove with the oil pump alignment mark. NOTICE: Always turn the crankshaft clockwise. (c) Check that timing marks of the camshaft timing pul– leys and No.3 timing belt cover are aligned. If not, turn the crankshaft 1 revolution (360°). (d) Remove the crankshaft pulley bolt. EG2–45 1MZ–FE ENGINE – ENGINE MECHANICAL 18. IF REUSING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT Check that there are 3 installation marks and front mark on the timing belt. If the installation and front marks have disappeared, before removing the timing belt, place new installation and front marks on the timing belt to the following position: • Timing mark of RH camshaft timing pulley • Timing mark of LH camshaft timing pulley • Dot mark of crankshaft timing pulley 19. REMOVE TIMING BELT TENSIONER Alternately loosen the 2 bolts, and remove them, the tensioner and dust boot. 20. REMOVE TIMING BELT 21. REMOVE CAMSHAFT TIMING PULLEYS (a) Using SST, remove the bolt and RH timing pulley. SST 09249 – 63010, 09960 –10010 (09962 – 01000) EG2–46 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Using SST, remove the LH timing pulley. SST 09960–10010 (09962–01000) HINT: Arrange the camshaft timing pulleys (RH and LH sides). 22. REMOVE NO.2 IDLER PULLEY Remove the bolt and idler pulley. 23. REMOVE No.1 IDLER PULLEY Using a 10 mm hexagon wrench, remove the bolt, idler pulley and plate washer. 24. REMOVE CRANKSHAFT TIMING PULLEY (a) Remove the bolt and timing belt plate. EG2–47 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Using SST, remove the crankshaft timing pulley. SST 09213–60017 (09213–00020, 09213–00030, 09213–00050) NOTICE: Do not scratch the sensor part of the crankshaft timing pulley. TIMING BELT INSPECTION 1. INSPECT TIMING BELT NOTICE: • Do not bend, twist or turn the timing belt inside out. • Do not allow the timing belt to come into contact with oil, water or steam. • Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley. If there are any defects, as shown in the illustrations, check the following points: (a) Premature parting • Check for proper installation. • Check the timing cover gasket for damage and proper installation. (b) If the belt teeth are cracked or damaged, check to see if either camshaft is locked. (c) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump. EG2–48 1MZ–FE ENGINE – ENGINE MECHANICAL (d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. (e) If there is noticeable wear on the belt teeth, check timing cover for damage and check gasket has been installed correctly and for foreign material on the pulley teeth. If necessary, replace the timing belt. 2. INSPECT IDLER PULLEYS Check that the idler pulley turns smoothly. If necessary, replace the idler pulley. 3. INSPECT TIMING BELT TENSIONER (a) Visually check tensioner for oil leakage. HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner. P12429 (b) Hold the tensioner with both hands and push the push rod strongly as shown to check that it doesn’t move. If the push rod moves, replace the tensioner. NOTICE: Never hold the tensioner push rod facing down– ward. EG2–49 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Measure the protrusion of the push rod from the housing end. Protrusion: 10.0 – 10.8 mm (0.394 – 0.425 In.) If the protrusion is not as specified, replace the tensi– oner. TIMING BELT INSTALLATION (See Components for Removal and Installation) 1. INSTALL CRANKSHAFT TIMING PULLEY (a) Align the pulley set key with the key groove of the timing pulley and slide on the timing pulley. (b) Using SST and a hammer, tap in the timing pulley, facing the sensor side rearward. SST 09223–46011 NOTICE: Do not scratch the sensor part of the crankshaft timing pulley. (c) Install the timing belt plate with the bolt. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) 2. INSTALL NO.1 IDLER PULLEY (a) Using a 10 mm hexagon wrench, install the idler pulley with the plate washer and bolt. Torque: 34 N–m (350 kgf–cm, 25 ft–lbf) (b) Check that the pulley bracket moves smoothly. EG2–50 1MZ–FE ENGINE – ENGINE MECHANICAL 3. INSTALL No.2 IDLER PULLEY (a) Install the idler pulley with the bolt. Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) (b) Check that the idler pulley moves smoothly. 4. INSTALL RH CAMSHAFT TIMING PULLEY (a) Install the timing pulley, facing the flange side out– ward. (b) Align the knock pin hole of the camshaft with the knock pin groove of the timing pulley as shown. (c) Using SST, install and torque the bolt. SST 09249–63010, 09960–10010 (09962–01000) Torque: 88 N–m (900 kgf–cm, 65 ft–lbf) HINT: Use a torque wrench with a fulcrum length of 340 mm (113.39 in.) 5. INSTALL LH CAMSHAFT TIMING PULLEY (a) Install the timing pulley, facing the flange side inward. (b) Align the knock pin hole of the camshaft with the knock pin groove of the timing pulley as shown. (d) Using SST, install and torque the bolt. SST 09960–10010 (09962–01000) Torque: 126 N–m (1,300 kgf–cm, 94 ft–lbf) EG2–51 1MZ–FE ENGINE – ENGINE MECHANICAL 6. SET NO.1 CYLINDER TO TDC/COMPRESSION (a) Crankshaft Timing Pulley Position: Temporarily install the crankshaft pulley bolt to the crankshaft. Turn the crankshaft and align the crankshaft timing pulley groove with the oil pump alignment mark. (b) RH Camshaft Timing Pulley Position: Using SST, turn the camshaft pulley, align the timing marks of the camshaft and the No.3 timing belt cover. SST 09960–10010 (09962–01000) (c) LH Camshaft Timing Pulley Position: Using SST, turn the camshaft pulley, align the timing marks of the camshaft and the No.3 timing belt cover. SST 09960 –10010 (09962 – 01000) 7. INSTALL TIMING BELT NOTICE: The engine should be cold. (a) Remove any oil or water on the pulleys, and keep them clean. (b) Check the timing belt front mark. (c) Align the installation mark on the timing belt with the dot mark of the crankshaft timing pulley. (d) Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys. (e) Install the timing belt with the following order: • Crankshaft timing pulley • Water pump pulley • LH camshaft timing pulley • No.2 idler pulley • RH camshaft timing pulley • No.1 idler pulley EG2–52 1MZ–FE ENGINE – ENGINE MECHANICAL 8. SET TIMING BELT TENSIONER (a) Using a press, slowly press in the push rod using 981 –9,807 N (1100–1,000 kgf, 200–2,205 Ibf) of pres– sure. (b) Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod. (c) Release the press. (d) Install the dust boot to the tensioner. 9. INSTALL TIMING BELT TENSIONER (a) Temporarily install the tensioner with the 2 bolts. (b) Alternately tighten the 2 bolts. Torque: 27 N–m (280 kgf–cm, 20 ft–lbf) (c) Remove the 1.27 mm hexagon wrench from the tensi– oner. 10. CHECK VALVE TIMING (a) Turn the crankshaft, and align the crankshaft timing pulley groove with the oil pump alignment mark. NOTICE: Always turn the crankshaft clockwise. EG2–53 1MZ–FE ENGINE – FE ENGINE – ENGINE MECHANICAL (b) Check that the timing marks of the RH and LH timing pulleys with the timing marks of the No.3 timing belt cover as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it. (c) Remove the crankshaft pulley bolt. 11. INSTALL TIMING BELT GUIDE Install the belt guide, facing the cup side outward. 12. INSTALL ENGINE RH MOUNTING BRACKET Install the mounting bracket with the 2 bolts and nut. Torque: 28 N–m (290 kgf–cm, 21 ft–lbf) 13. INSTALL N0.2 TIMING BELT COVER (a) Check that the timing belt cover gasket has no cracks or peeling, etc. If the gasket does have cracks or peeling, etc., replace it using following steps. (1) Using a screwdriver and gasket scraper, remove all the old gasket material. (2) Thoroughly clean all components to remove all the loose material. (3) Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded black in the illustration. (4) After installing the gasket, press down on it sc that the adhesive firmly sticks to the belt cover. (b) Install new gasket to the No.2 belt cover. EG2–54 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Install the belt cover with the 5 bolts. Torque: 8.5 N–m (85 kgf–cm. 74 in.–lbf) 14. CONNECT ENGINE WIRE (a) Connect the engine wire with the clamp. (b) Install the bolt holding the engine wire to the No.3 timing belt cover. 15. INSTALL NO.1 TIMING BELT COVER (a) Check that the timing belt cover gaskets have cracks or peeling, etc. If the gasket does have cracks or peeling, etc., replace it using following steps, peeling, etc., replace them using following steps. (1) Using a screwdriver and gasket scraper, remove all the old gasket material. (2) Thoroughly clean all components to remove all the loose material. (3) Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded back in the illustration. NOTICE: When joining 2 gaskets, do not leave a gap between them. Cut off any excess gasket. (4) After installing the gasket, press down on it so that the adhesive firmly sticks to the belt cover. (b) Install new gaskets to the No.1 belt cover. (c) Install the belt cover with the 4 bolts. Torque: 8.5 N–m (85 kgf–cm, 74 in.–lbf) EG2–55 1MZ–FE ENGINE – ENGINE MECHANICAL 16. INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key with the key groove of the pulley, and slide the pulley. (b) Using SST, install and torque the bolt. SST 09213–54015, 09330–00021 Torque: 216 N–m (2,200 kgf–cm, 159 ft–lbf) 17. INSTALL NO.2 GENERATOR BRACKET Install the bracket with the pivot bolt and nut. Do not tighten the bolt yet. Torque: 28 N–m (290 kgf–cm, 21 ft–lbf) for Nut 18. INSTALL NO.2 RH ENGINE MOUNTING BRACKET AND ENGINE MOVING CONTROL ROD Install the mounting bracket and control rod with the 3 bolts. Torque: 63.7 N–m (650 kgf–cm, 47 ft–lbf) 19. INSTALL RH ENGINE MOUNTING STAY Install the mounting stay with the 3 bolts. Torque: 31.4 N–m (320 kgf–cm. 23 ft–lbf) 24. CONNECT GROUND STRAPS Connect the 2 straps. EG2–56 1MZ–FE ENGINE – FE ENGINE – ENGINE MECHANICAL 21. INSTALL AND ADJUST PS DRIVE BELT Install the drive belt with the pivot and adjusting bolts. Drive belt tension: New belt 150 ± 185 I bf Used belt 115 ± 20 lbf 22. INSTALL GENERATOR DRIVE BELT Adjust the drive belt. (See CH section) Drive belt tension: New belt 175 ± 5 lbf Used belt 115 ± 20 lbf 23. INSTALL COOLANT RESERVOIR TANK 24. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 25. START ENGINE, AND CHECK FOR ABNORMAL NOISE AND SMOOTH OPERATION 26. INSTALL RH FENDER APRON SEAL 27. INSTALL RH FRONT WHEEL EG2–57 1MZ–FE ENGINE – ENGINE MECHANICAL CYLINDER HEAD COMPONENTS FOR REMOVAL AND INSTALLATION EG2–58 1MZ–FE ENGINE – ENGINE MECHANICAL EG2–59 1MZ–FE ENGINE – ENGINE MECHANICAL EG2–60 1MZ–FE ENGINE – ENGINE MECHANICAL EG2–61 1MZ–FE ENGINE – ENGINE MECHANICAL EG2–62 1MZ–FE ENGINE – ENGINE MECHANICAL CYLINDER HEADS REMOVAL (See Components for Removal and Installation) 1. REMOVE BATTERY AND TRAY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. DRAIN ENGINE COOLANT 3. DISCONNECT ACCELERATOR CABLE 4. DISCONNECT THROTTLE CABLE 5. REMOVE AIR CLEANER CAP, VOLUME AIR FLOW METER AND AIR CLEANER HOSE (a) Disconnect the volume air flow meter connector and wire clamp. (b) Disconnect the accelerator cable clamp. (c) Disconnect the PCV hose. (d) Loosen the air cleaner hose clamp bolt. (e) Disconnect the 4 air cleaner cap clips. (f) Remove the air cleaner cap and volume air flow meter together with the air cleaner hose. 6. w/ CRUISE CONTROL SYSTEM: REMOVE CRUISE CONTROL ACTUATOR (a) Remove the bolt, clip and actuator cover. (b) Disconnect the actuator connector and clamp. (c) Remove the 3 bolts, and disconnect the actuator with the bracket. 7. DISCONNECT GROUND STRAPS Disconnect the 2 straps. EG2–63 1MZ–FE ENGINE – ENGINE MECHANICAL 8. REMOVE RH ENGINE MOUNTING STAY Remove the 3 bolts and RH engine mounting stay. 9. DISCONNECT RADIATOR HOSES 10. DISCONNECT HEATER HOSES Disconnect the 2 hoses. 11. DISCONNECT FUEL HOSES Disconnect the fuel inlet and return hoses. CAUTION: Catch leaking fuel in a container. 12. DISCONNECT PRESSURE HOSE OF HYDRAULIC MOTOR Remove the bolt, and disconnect the pressure hose from the water inlet. EG2–64 1MZ–FE ENGINE – FE ENGINE – ENGINE MECHANICAL 13. REMOVE V – BANK COVER Using a 5 mm hexagon wrench, remove the 2 nuts and V–bank cover. 14. REMOVE EMISSION CONTROL VALVE SET (a) Disconnect the following vacuum hoses: (1) Vacuum hose from fuel pressure control VSV (2) Vacuum hose from fuel pressure regulator (3) Vacuum hose from cylinder head rear plate (4) Vacuum hose from intake air control valve VSV (5) Vacuum hose from EGR vacuum modulator (6) Vacuum hose from EGR valve (b) Disconnect the following connectors: (1) Intake air control valve connector (2) Fuel pressure connector (3) EGR VSV connector (c) Remove the 2 nuts and emission control valve set. 15. REMOVE AIR INTAKE CHAMBER (a) Disconnect the following hoses: (1) Brake booster vacuum hose (2) PCV hose (3) Intake air control valve vacuum hose (b) Disconnect the data link connector 1. (c) Remove the nut and disconnect the 2 ground straps. EG2–65 1MZ–FE ENGINE – FE ENGINE – ENGINE MECHANICAL (d) Remove the bolt and disconnect the hydraulic motor pressure hose from the air intake chamber. (e) Remove the bolt, and disconnect the ground strap. (f) Disconnect the RH oxygen sensor connector clamp from the PS pressure tube. (g) Remove the 2 nuts, and disconnect the PS pressure tube. (h) Disconnect the 2 PS air hoses. (i) Remove the 2 bolts and No.1 engine hanger. (j) Remove the 2 bolts and air intake chamber stay. (k) Remove the 4 nuts, EGR pipe and 2 gaskets. EG2–66 1MZ–FE ENGINE – ENGINE MECHANICAL (I) Disconnect the following connectors: (1) Throttle position sensor connector (2) IAC valve connector (3) EGR gas temperature sensor connector (4) A/C idle–up connector (m) Disconnect the following vacuum hoses: (1) 2 vacuum hoses from TVV (2) Vacuum hose from cylinder head rear plate (3) Vacuum hose from charcoal canister (n) Disconnect the following hoses: (1) 2 water bypass hoses (2) Air assist hose (o) Using an 8 mm hexagon wrench, remove the 2 bolts, 2 nuts, air intake chamber and gasket. EG2–67 1MZ–FE ENGINE – ENGINE MECHANICAL 16. REMOVE INTAKE AIR CONTROL VALVE FROM AIR INTAKE CHAMBER (a) Disconnect the A/C air hose. (b) Remove the 3 nuts and data link connector 1 clamp. (c) Remove the intake air control valve by prying a screw– driver between the intake air control valve and air intake chamber. (d) Remove the gasket. 17. REMOVE A/C IDLE–UP VSV FROM AIR INTAKE CHAMBER (a) Disconnect the air hose. (b) Remove the 2 bolts and A/C idle–up VSV. 18. REMOVE THROTTLE BODY FROM AIR INTAKE CHAMBER (a) Disconnect the following vacuum hoes: (1) Vacuum hose from P port of EGR vacuum modu– lator (2) Vacuum hose from R port of EGR vacuum modu– lator (b) Remove the 2 bolts, 2 nuts, throttle body and gasket. 19. REMOVE EGR VALVE AND VACUUM MODULATOR FROM AIR INTAKE CHAMBER Remove the 3 nuts, EGR valve, vacuum modulator and gasket. 20. DISCONNECT ENGINE WIRE FROM ENGINE LH SIDE (a) Disconnect the following connectors: (1) 3 injector connectors (2) 3 ignition coil connectors (b) Remove the 2 nuts, and disconnect the engine wire. EG2–68 1MZ–FE ENGINE – ENGINE MECHANICAL 21. DISCONNECT ENGINE WIRE FROM NO.3 TIMING BELT COVER Disconnect the 2 clamps and engine wire. 22. DISCONNECT ENGINE WIRE FROM ENGINE REAR SIDE (a) Disconnect the following connectors: (1) LH oxygen sensor (2) Engine coolant temperature sensor (3) Camshaft position sensor (b) Disconnect the 3 clamps. (c) Remove the 2 nuts, and disconnect the engine wire. 23. DISCONNECT ENGINE WIRE FROM ENGINE RH SIDE (a) Disconnect the following connectors: (1) 3 injector connectors (2) 3 ignition coil connectors (3) Water temperature sender gauge connector (4) Water temperature sensor connector (5) RH oxygens sensor connector (b) Remove the 5 nuts, and disconnect the engine wire. EG2–69 1MZ–FE ENGINE – ENGINE MECHANICAL 24. REMOVE IGNITION COILS Remove the6 bolts and6 ignition coils from the RH and LH cylinder heads. HINT: Arrange the ignition coils in the correct order. 25. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the6 spark plugs from the RH and LH cylinder heads. 26. REMOVE FRONT EXHAUST PIPE (a) Remove the 2 bolts and front exhaust pipe clamp. (b) Remove the 2 bolts, and disconnect the bracket. (c) Remove the 2 bolts and 2 nuts holding the front exhaust pipe to the three–way catalytic converter. (d) Remove the 4 nuts holding the front exhaust pipe to the exhaust manifolds. (e) Remove the front exhaust pipe and gaskets. EG2–70 1MZ–FE ENGINE – ENGINE MECHANICAL 27. REMOVE TIMING BELT (See steps 2 to 20 on pages EG2–41 to 45) 28. REMOVE CAMSHAFT TIMING PULLEYS (a) Using SST, remove the bolt and RH timing pulley. SST 09249–63010, 09960–10010 (09862–01000) (b) Using SST, remove the LH timing pulley. SST 09960–10010 (09962–01000) HINT: Arrange the camshaft timing pulleys (RH and LH sides). 29. REMOVE NO.2 IDLER PULLEY Remove the bolt and idler pulley. EG2–71 1MZ–FE ENGINE – ENGINE MECHANICAL 30. REMOVE NO.3 TIMING BELT COVER Remove the 6 bolts and belt cover. 31. REMOVE CYLINDER HEAD REAR PLATE (a) Disconnect the vacuum hose from the vacuum tank. (b) Remove the nut, and disconnect the ground strap. (c) Remove the bolt and rear plate. 32. REMOVE WATER INLET PIPE (a) Remove the bolt and inlet pipe. (b) Remove the O–ring. 33. REMOVE AIR ASSIST HOSE AND VACUUM HOSE 34. REMOVE INTAKE MANIFOLD, DELIVERY PIPES AND INJECTORS Remove the 9 bolts, 2 nuts, 2 plate washers and intake manifold together with the delivery pipes, and injectors. EG2–72 1MZ–FE ENGINE – ENGINE MECHANICAL 35. REMOVE FUEL PRESSURE REGULATOR FROM LH DELIVERY PIPE (a) Remove the 2 bolts, and pull out the pressure regula– tor. (b) Remove the 0–ring from the pressure regulator. 36. REMOVE TVV FROM INTAKE MANIFOLD 37. REMOVE FUEL PULSATION DAMPER AND No.1 FUEL PIPE Remove the bolt, pulsation damper, No. 1 fuel pipe and 2 gaskets. 38. REMOVE No.2 FUEL PIPE Remove the 2 union bolts, No.2 fuel pipe and 4 gas– kets. 39. REMOVE DELIVERY PIPES AND INJECTORS (a) Remove the 4 bolts, delivery pipes together with the 6 injectors. NOTICE: Be careful not to drop the injectors when rem– oving the delivery pipes. (b) Remove the 4 spacers from the intake manifold. EG2–73 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Pull out the 6 injectors from the delivery pipes. Remove the 0–ring and grommet from each injector. 40. REMOVE WATER OUTLET (a) Remove the 2 bolts, 2 nuts and 2 plate washers. (b) Disconnect the water bypass hose and remove the water outlet. (c) Remove the 2 intake manifold gaskets. 41. REMOVE No.2 ENGINE HANGER Remove the 2 bolts and engine hanger. 42. REMOVE LH EXHAUST MANIFOLD (a) Remove the main heated oxygen sensor (Bank 2 Sensor 1). (b) Remove the bolt, nut and exhaust manifold stay. EG2–74 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Remove the 6 nuts, exhaust manifold and gasket. 43. REMOVE OIL DIPSTICK AND GUIDE (a) Remove the bolt holding the dipstick guide to the LH cylinder head. (b) Pull out the dipstick guide together with the dipstick from the No.1 oil pan. (c) Remove 0–ring from the dipstick guide. 44. REMOVE PS BRACKET Remove the 3 bolts and PS bracket. 45. REMOVE RH EXHAUST MANIFOLD (a) Remove the main heated oxygen sensor (Bank 1 Sensor 1). (b) Remove the 4 nuts, EGR pipe and 2 gaskets. EG2–75 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Remove the bolts, 2 nuts, exhaust manifold stay and exhaust manifold plate. (d) Remove the 6 nuts, exhaust manifold and gasket. 46. REMOVE CYLINDER HEAD COVERS Remove the 8 bolts, cylinder head cover and gasket. Remove the 2 cylinder head covers. 47. REMOVE CAMSHAFT POSITION SENSOR (a) Remove the bolt and position sensor. (b) Remove the gasket from the position sensor. 48. REMOVE CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. EG2–76 1MZ–FE ENGINE – FE ENGINE – ENGINE MECHANICAL A. Remove intake camshaft of RH cylinder head (a) Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench. (b) Secure the exhaust camshaft sub–gear to the main gear with a service bolt. Recommended service bolt: Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16–20 mm HINT: When removing the camshaft, mark certain that the torsional spring force of the sub–gear has been eliminated by the above operation. (c) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. (d) Remove the 5 bearing caps and intake camshaft. B. Remove exhaust camshaft of RH cylinder head (a) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. (b) Remove the 5 bearing caps, oil seal and exhaust cam– shaft. C. Remove intake camshaft of LH cylinder head (a) Align the timing marks (11 dot mark) of the camshaft drive and driven gears by turning the camshaft with a wrench. EG2–77 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Secure the exhaust camshaft sub–gear to the main gear with a service bolt. Recommended service bolt: Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16–20 mm HINT: When removing the camshaft, make sure that the torsional spring force of the sub–gear has been eliminated by the above operation. (c) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. (d) Remove the 5 bearing caps and intake camshaft. D. Remove exhaust camshaft of LH cylinder head (a) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown. (b) Remove the 5 bearing caps, oil seal and exhaust cam– shaft. HINT: • Arrange the camshafts in the correct order. • Arrange the bearing caps in the correct order. EG2–78 1MZ–FE ENGINE – ENGINE MECHANICAL 49. DISASSEMBLE EXHAUST CAMSHAFTS (a) Mount the hexagonal wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. (b) Using SST, turn the sub–gear counterclockwise, and remove the service bolt. SST 09960–10010 (09962–0100) (c) Using snap ring pliers, remove the snap ring. (d) Remove the following parts: (1) Wave washer (2) Camshaft sub–gear (3) Camshaft gear spring HINT: Arrange the camshaft sub–gears and gear spr– ings (RH and LH sides). EG2–79 1MZ–FE ENGINE – ENGINE MECHANICAL 50. REMOVE CYLINDER HEADS (a) Using a 8 mm hexagon wrench, remove the cylinder head (recessed head) bolt on each cylinder head, then repeat for the other side, as shown. (b) Uniformly loosen and remove the 8 cylinder head (12 pointed head) bolts on each cylinder head, in several passes, in the sequence shown, then repeat for the other side, as shown. Remove the 16 cylinder head bolts and plate washers. NOTICE: Head warpage or cracking could result from removing bolts in an incorrect order. (c) Lift the cylinder head from the dowels on the cylinder block and place the 2 cylinder heads on wooden blocks on a bench. HINT: If the cylinder head is difficult to lift off, pry with a screwdriver between the cylinder head and cylinder block saliences. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. EG2–80 1MZ–FE ENGINE – ENGINE MECHANICAL CYLINDER HEAD DISASSEMBLY (See Components for Removal and Installation) 1. REMOVE VALVE LIFTERS AND SHIMS HINT: Arrange the valve lifters and shims in the cor– rect order. 2. REMOVE VALVES (a) Using SST, compress the valve spring and remove the 2 keepers. SST 09202 – 70010 (b) Remove the following parts: (1) Spring retainer (2) Valve spring (3) Valve (c) Using needle–nose pliers, remove the oil seal. EG2–81 1MZ–FE ENGINE – ENGINE MECHANICAL (d) Using compressed air and a magnetic finger, remove the spring seat by blowing air. HINT: Arrange the valves, valve springs, spring seats and spring retainers in the correct order. CYLINDER HEAD COMPONENTS INSPECTION AND REPAIR 1. CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK (a) Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface. (b) Using a gasket scraper, remove all the gasket material from the cylinder block surface. (c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed air. 2. CLEAN CYLINDER HEAD A. Remove gasket material Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface. EG2–82 1MZ–FE ENGINE – ENGINE MECHANICAL B. Clean combustion chambers Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact surface. C. Clean cylinder head Using a soft brush and solvent, thoroughly clean the cylinder head. D. Clean valve guide bushings Using a valve guide bushing brush and solvent, clean all the guide bushings. 3. INSPECT CYLINDER HEAD A. Inspect for flatness Using a precision straight edge and feeler gauge, mea– sure the surfaces contacting the cylinder block and the manifolds for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the cylin– der head. EG2–83 1MZ–FE ENGINE – ENGINE MECHANICAL B. Inspect for cracks Using a dye penetrant, check the combustion cham– ber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. 4. CLEAN VALVES (a) Using a gasket scraper, chip off any carbon from the valve head. (b) Using a wire brush, thoroughly clean the valve. 5. INSPECT VALVE STEMS AND GUIDE BUSHINGS (a) Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 5.510 – 5.530 mm (0.2169 – 0.2177 in.) (b) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake 5.470 – 5.485 mm (0.2154 – 0.2159 in.) Exhaust 5.465 – 5.480 mm (0.2152 – 0.2157 in.) (c) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025 – 0.060 mm (0.0010 – 0.0024 in.) Exhaust 0.030 – 0.065 mm (0.0012 – 0.0026 in.) EG2–84 1MZ–FE ENGINE – ENGINE MECHANICAL Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the valve and guide bushing. 6. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS (a) Gradually heat the cylinder head to 80 – 100
C (176 – 212
F). (b) Using SST and a hammer, tap out the guide bushing. SST 09201– 01055, 09608–20012 (09608–03020) (c) Using a caliper gauge, measure the bushing bore di– ameter of the cylinder head. Both intake and exhaust Bushing bore diameter Bushing size mm (in.) 10.295 –10.313 Use STD (0.4053 – 0.4060) 10.345 – 10.363 (0.4073 – 0.4080) Use O/S 0.05 (d) Select a new guide bushing (STD or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 10.313 mm (0.4060 in.), machine the bushing bore to the following dimension: 10.345 – 10.363 mm (0.4073 – 0.4080 in.) If the bushing bore diameter of the cylinder head is greater than 10.363 mm (0.4080 in.), replace the cylinder head. EG2–85 1MZ–FE ENGINE – ENGINE MECHANICAL HINT: Different bushings are used for the intake and exhaust. (e) Gradually heat the cylinder head to 80 – 100
C (176 – 212
F). (f) Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. SST 09201– 01055, 09608–20012 (09608–03020) Protrusion height: Intake 11.1 – 11.3 mm (0.437 – 0.445 in.) Exhaust 8.9 – 9.3 mm (0.350 – 0.366 in.) (h) Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance (See step 5 above) between the guide bushing and valve stem. 7. INSPECT AND GRIND VALVES (a) Grind the valve enough to remove pits and carbon. (b) Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5
EG2–86 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Check the valve head margin thickness. Standard margin thickness: 1.0 mm (0.039 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than minimum, replace the valve. (d) Check the valve overall length. Standard overall length: Intake 95.45 mm (3.5779 in.) Exhaust 95.40 mm (3.7559 in.) Minimum overall length: Intake 94.95 mm (3.7382 in.) Exhaust 94.90 mm (3.7362 in.) If the overall length is less than minimum, replace the valve. (e) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. NOTICE: Do not grind off more than minimum. 8. INSPECT AND CLEAN VALVE SEATS (a) Using a 45
carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats. EG2–87 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve. (c) Check the valve face and seat for the following: • If blue appears 360
around the face, the valve is concentric. If not, replace the valve. • If blue appears 360
around the valve seat, the guide and face are concentric. If not, resurface the seat. • Check that the seat contact is in the middle of the valve face with the following width: 1.0 – 1.4 mm (0.039 – 0.055 In.) If not, correct the valve seats as follows: (1) If the seating is too high on the valve face, use 30
and 45
cutters to correct the seat. (2) If the seating is too low on the valve face, use 75
and 45
cutters to correct the seat. (d) Hand–lap the valve and valve seat with an abrasive compound. (e) After hand–lapping, clean the valve and valve seat. 9. INSPECT VALVE SPRINGS (a) Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than maximum, replace the valve spring. EG2–88 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Using a vernier caliper, measure the free length of the valve spring. Free length: 45.50 mm (1.7913 in.) If the free length is not as specified, replace the valve spring. (c) Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 186 – 206 N (19.0 – 21.0 kgf, 41.9 – 46.3 lbf) at 33.8 mm (1.331 in.) If the installed tension is not as specified, replace the valve spring. 10. INSPECT CAMSHAFTS AND BEARINGS A. Inspect camshaft for runout (a) Place the camshaft on V – blocks. (b) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the camshaft. B. Inspect cam lobes Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake 42.11 – 42.21 mm (1.6579 – 1.6618 in.) Exhaust 41.96 – 42.06 mm (1.6520 – 1.6559 in.) Minimum cam lobe height: Intake 41.96 mm (1.6520 in.) Exhaust 41.81 mm (1.6461 in.) If the cam lobe height is less than minimum, replace the camshaft. EG2–89 1MZ–FE ENGINE – ENGINE MECHANICAL C. Inspect camshaft journals Using a micrometer, measure the journal diameter. Journal diameter: 26.949 – 26.965 mm (1.0610 – 1.061 6 in.) If the journal diameter is not as specified, check the oil clearance. D. Inspect camshaft bearings Check that bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set. E. Inspect camshaft journal oil clearance (a) Clean the bearing caps and camshaft journals. (b) Place the camshafts on the cylinder head. (c) Lay a strip of Plastigage across each of the camshaft journals. (d) Install the bearing caps. (See step 3 on pages EG2–98 to 102) Torque: 16 N–m (160 kgf–cm, 12 ft–lbf) NOTICE: Do not turn the camshaft. (e) Remove the bearing caps. EG2–90 1MZ–FE ENGINE – ENGINE MECHANICAL (f) Measure the Plastigage at its widest point. Standard oil clearance: 0.035 – 0.072 mm (0.0014 – 0.0028 in.) Maximum oil clearance: 0.10 mm (0.0039 fn.) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (g) Completely remove the Plastigage. (h) Remove the camshafts. F. Inspect camshaft thrust clearance (a) Install the camshafts. (See step 3 on pages EG2–98 to 102) (b) Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust clearance: 0.040 – 0.090 mm (0.0016 – 0.0035 in.) Maximum thrust clearance: 0.12 mm (0.0047 in.) If the thrust clearance is greater than maximum, re– place the camshaft. If necessary, replace the bearing caps and cylinder head as a set. (c) Remove the camshafts. G. Inspect camshaft gear backlash (a) Install the camshafts without installing the exhaust cam sub–gear. (See step 3 on pages EG2–98 to 102) (b) Using a dial indicator, measure the backlash. Standard backlash: 0.020 – 0.200 mm (0.0008 – 0.0079 In.) Maximum backlash: 0.30 mm (0.0188 in.) If the backlash is greater then maximum, replace the camshafts. (c) Remove the camshafts. EG2–91 1MZ–FE ENGINE – ENGINE MECHANICAL H. Inspect camshaft gear spring Using a vernier caliper, measure the free distance between the spring ends. Free distance: 18.2 – 18.8 mm (0.712 – 0.740 in.) If the free distance is not as specified, replace the gear spring. 11. INSPECT VALVE LIFTERS AND LIFTER BORES (a) Using a caliper gauge, measure the lifter bore diame– ter of the cylinder head. Lifter bore diameter: 31.000 – 31.018 mm (1.2205 – 1.2212 in.) (b) Using a micrometer, measure the lifter diameter. Lifter diameter: 30.966 – 30.976 mm (1.2191 – 1.2196 in.) (c) Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024 – 0.050 mm (0.0009 – 0.0020 in.) Maximum oil clearance: 0.07 mm (0.0028 In.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head. 12. INSPECT AIR INTAKE CHAMBER Using a precision straight edge and feeler gauge, mea– sure the surface contacting the intake manifold for warpage. Maximum warpage: 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the cha– mber. EG2–92 1MZ–FE ENGINE – ENGINE MECHANICAL 13. INSPECT INTAKE MANIFOLD Using a precision straight edge and feeler gauge, mea– sure the surface contacting the cylinder head and air intake chamber for warpage. Maximum warpage: Air Intake Chamber Side 0.15 mm (0.0059 in.) Cylinder Head Side 0.08 mm (0.0031 in.) If warpage is greater than maximum, replace the man– ifold. 14. INSPECT EXHAUST MANIFOLD Using a precision straight edge and feeler gauge, mea– sure the surface contacting the cylinder head for war– page. Maximum warpage: 0.50 mm (0.0196 in.) If warpage is greater than maximum, replace the man– ifold. 15. INSPECT CYLINDER HEAD BOLTS (for 12 Pointed Head Bolts) Using a caliper gauge, measure the thread outside diameter of the bolt. Standard outside diameter: 8.95 – 9.05 mm (0.3524 – 0.3563 in.) Minimum outside diameter: 8.75 mm (0.3445 in.) If the diameter is less than minimum, replace the bolt. EG2–93 1MZ–FE ENGINE – ENGINE MECHANICAL 16. IF NECESSARY, REPLACE SPARK PLUG TUBE GASKETS (a) Bend up the tab on the ventilation baffle plate which prevents the gasket from the slipping out. (b) Using a screwdriver and hammer, tap out the gasket. (c) Using needle–nose pliers, ply out the gasket. (d) Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover. SST 09608–20012 (09608–03070) (e) Apply a light coat of MP grease to the gasket lip. (f) Return the ventilation plate tab to its original position. CYLINDER HEAD ASSEMBLY (See Components for Removal and Installation) HINT: • Thoroughly clean all parts to be assembled. • Before installing the parts, apply new engine oil to all sliding and rotating surfaces. • Replace all gaskets and oil seals with new ones. 1. INSTALL SPARK PLUG TUBES HINT: When using a new cylinder head, spark plug tubes must be installed. (a) Apply adhesive to the end of the spark plug tube. Adhesive: Part No. 08833–00070, THREE BOND 1324 or equivalent EG2–94 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Using a press, press in a new spark plug tube until there is 42.4 – 43.4 mm (1.669 – 1.749) protruding from the camshaft bearing cap installation surface of the cylinder head. NOTICE: Avoid pressing a new spark plug tube In too far by measuring the amount of the protrusion while press– ing. 2. INSTALL PCV PIPES HINT: When using a new cylinder head, PCV pipe must be installed. Using a wooden block and hammer, tap in a new spark tube until its top side is flush with the cylinder head edge. NOTICE: Be careful not to damage the cylinder head edge. 3. INSTALL VALVES (a) Using SST, push in a new oil seal. SST 09201 –41020 HINT: The intake valve oil seal is silver and the ex– haust valve oil seal is black. (b) Install the following parts: (1) Valve (2) Spring seat (3) Valve spring (4) Spring retainer EG2–95 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Using SST, compress the valve spring and place the 2 keepers around the valve stem. SST 09202 – 70010 (d) Using a plastic–faced hammer, lightly tap the valve stem tip to ensure a proper fit. 4. INSTALL VALVE LIFTERS AND SHIMS (a) Install the valve lifter and shim. (b) Check that the valve lifter rotates smoothly by hand. EG2–96 1MZ–FE ENGINE – ENGINE MECHANICAL CYLINDER HEAD INSTALLATION (See Components for Removal and Installation) 1. INSTALL CYLINDER HEADS A. Place cylinder head on cylinder block (a) Place 2 new cylinder head gaskets in position on the cylinder block. NOTICE: Be careful of the installation direction. (b) Place the 2 cylinder heads in position on the cylinder head gaskets. B. Install cylinder head (12 pointed head) bolts HINT: • The cylinder head bolts are tightened in 2 pro– gressive steps (steps (b) and (d)). • If any bolt is broken or deformed, replace it. (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (b) Install and uniformly tighten the . cylinder head bolts on each cylinder head, in several passes, in the se– quence shown, then repeat for the other side, as shown. Torque: 64 N–m (550 kgf–cm, 40 ft–lbf) If any of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. (c) Mark the front of the cylinder head bolt head with paint. (d) Retighten the cylinder head bolts by 90
in the numer– ical order shown. (e) Check that the painted mark is now at a 90
angle to the front. EG2–97 1MZ–FE ENGINE – ENGINE MECHANICAL C. Install cylinder head (recessed head) bolts (a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (b) Using a 8 mm hexagon wrench, install the cylinder head bolt on each cylinder head, then repeat for the other side, as shown. Torque: 18.5 N–m (185 kgf–cm, 13 ft–lbf) 2. ASSEMBLY EXHAUST CAMSHAFTS (a) Mount the hexagonal wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. (b) Install the following parts: (1) Camshaft gear spring (2) Camshaft sub–gear (3) Wave washer (c) Using snap ring pliers, install the snap ring. EG2–98 1MZ–FE ENGINE – ENGINE MECHANICAL (d) Using SST, align the holes of the camshaft main gear and sub–gear by turning camshaft sub–gear coun– terclockwise, and install a service bolt. SST 09960–10010 (09962–0100) HINT: Align the pins on the gears with the gear spring ends. 3. INSTALL CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it Is being installed. If the camshaft Is not level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. A. Install exhaust camshaft of RH cylinder head (a) Apply new engine oil to the thrust portion and journal of the camshaft. (b) Place the exhaust camshaft at 90
angle of timing mark (2 dot marks) on the cylinder head. (c) Apply MP grease to a new oil seal lip. (d) Install the oil seal to the camshaft. EG2–99 1MZ–FE ENGINE – ENGINE MECHANICAL (e) Remove any old packing (FIPG) material. (f) Apply seal packing to the No. 1 bearing cap as shown. Seal packing: Part No. 08826–00080 or equivalent (g) Install the 5 bearing caps in their proper locations. (h) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. (i) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown. Torque: 16 N–m (160 kgf–cm, 12 ft–lbf) B. Install intake camshaft of RH cylinder head (a) Apply new engine oil to the thrust portion and journal of the camshaft. (b) Align the timing marks (2 dot marks) of the camshaft drive and driven gears. (c) Place the intake camshaft on the cylinder head. (d) Install the 5 bearing caps in their proper locations. EG2–100 1MZ–FE ENGINE – ENGINE MECHANICAL (e) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. (f) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown. Torque: 16 N–m (160 kgf–cm, 12 ft–Ibf) (g) Remove the service bolt C. Install exhaust camshaft of LH cylinder head (a) Apply MP grease to the thrust portion of the cam– shaft. (b) Place the intake camshaft at 90
angle of timing mark (1 dot mark) on the cylinder head. (c) Apply MP grease to a new oil seal lip. EG2–101 1MZ–FE ENGINE – ENGINE MECHANICAL (d) Install the oil seal to the camshaft. (e) Remove any old packing (FIPG) material. (f) Apply seal packing to the No. 1 bearing cap as shown. Seal packing: Part No. 08826–00080 or equivalent (g) Install the 5 bearing caps in their proper locations. (h) Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts. (i) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown. Torque: 16 N–m (160 kgf–cm, 12 ft–lbf) D. Install intake camshaft of LH cylinder head (a) Apply MP grease to the thrust portion of the cam– shaft. (b) Align the timing marks (1 dot mark) of the camshaft drive and driven gears. (c) Place the intake camshaft on the cylinder head. EG2–102 1MZ–FE ENGINE – ENGINE MECHANICAL (d) Install the 5 bearing caps in their proper locations. (e) Apply a light coat of engine oil on the threads and under the heads of bearing cap bolts. (f) Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown. Torque: 16 N–m (160 kgf–cm, 12 ft–lbf) (g) Remove the service bolt. 4. CHECK AND ADJUST VALVE CLEARANCE (See steps 17 to 19 on pages EG2–18 to 23) Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance. Valve clearance (Cold): Intake 0.15 – 0.25 mm (0.006 – 0.010 in.) Exhaust 0.25–0.35mm(0.010–0.014in.) 6. INSTALL SEMI–CIRCULAR PLUGS (a) Remove any old packing (FIPG) material. (b) Apply seal packing to the semi–circular plug grooves, Seal packing: Part No. 08826–00080 or equivalent EG2–103 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Install the 4 semi–circular plugs to the cylinder heads. 6. INSTALL CAMSHAFT POSITION SENSOR (a) Install a new gasket to the position sensor. (b) Install the positron sensor with the bolt. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) 7. INSTALL CYLINDER HEAD COVERS (a) Apply seal packing to the cylinder heads as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent EG2–104 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Install the gasket to the cylinder head cover. (c) Install the cylinder head cover with the 8 bolts. Uni– formly tighten the bolts in several passes. Install the 2 cylinder head covers. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) 8. INSTALL RH EXHAUST MANIFOLD (a) Install a new gasket and the exhaust manifold with the 6 nuts. Torque: 49 N–m (500 kgf–cm, 36 ft–lbf) (b) Install the exhaust manifold stay and plate with the bolt and 2 nuts. Torque: 19.5 N–m (200 kgf–cm, 14 ft–lbf) HINT: Install the manifold stay so that the tip of the stay touches the head of the differential retainer in– stalllation bolt as shown in the illustration. (c) Install 2 new gaskets and the EGR pipe with the 4 nuts. Torque: 12 N–m (120 kgf–cm, 9 ft–lbf) (d) Install the main heated oxygen sensor (Bank 1 Sensor 1). Torque: 44 N–m (450 kgf–cm, 33 ft–lbf) EG2–105 1MZ–FE ENGINE – ENGINE MECHANICAL 9. INSTALL PS BRACKET Install the PS bracket with the 3 bolts. Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) 10. INSTALL OIL DIPSTICK AND GUIDE (a) Install a new O–ring to the dipstick guide. (b) Apply soapy water to the 0– ring. (c) Push in the dipstick guide end into the guide hole of the No. 1 oil pan. (d) Install the dipstick guide with the bolt. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) (e) Install the dipstick. 11. INSTALL LH EXHAUST MANIFOLD (a) Install a new gasket and the exhaust manifold with the 6 nuts. Torque: 49 N–m (500 kgf–cm, 36 ft–lbf) (b) Install the exhaust main manifold stay with the bolt and nut. Torque: 19.5 N–m (200 kgf–cm, 14 ft–lbf) (c) Install the main heated oxygen sensor (Bank 2 Sensor 1). Torque: 44 N–m (450 kgf–cm, 33 ft–lbf) EG2–106 1MZ–FE ENGINE – ENGINE MECHANICAL 12. INSTALL No.2 ENGINE HANGER Install the engine hanger with the 2 bolts. Torque: 19.5 N–m (200 kgf–cm, 14 ft–lbf) 13. INSTALL WATER OUTLET (a) Connect the water outlet to the bypass hose. (b) Install 2 new gaskets and the water outlet with the 2 bolts, 2 nuts and 2 plate washers. Torque: 15 N–m (150 kgf–cm, 11 ft–lbf) NOTICE: Do not scratch the seal surface of the water outlet with the stud bolt. 14. INSTALL INJECTORS AND DELIVERY PIPES (a) Install 2 new grommets to each injector. (b) Apply a light coat of gasoline to 2 new 0–rings and install them to each injector. (c) While turning the injector clockwise and counter– clockwise, push it to the delivery pipes. Install the 6 injectors. (d) Position the injector connector outward. (e) Place the 4 spacers in position on the intake manifold. EG2–107 1MZ–FE ENGINE – ENGINE MECHANICAL (f) Place the delivery pipes together with the 6 injectors in position on the intake manifold. (g) Temporarily install the 4 bolts holding the delivery pipes to the intake manifold. (h) Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of O–rings. Replace the O–rings. (i) Position the injector connector outward. (j) Tighten the 4 bolts holding the delivery pipes to the intake manifold. Torque: 10 N–m (100 kgf–cm, 7 ft–lbf) 15. INSTALL No.2 FUEL PIPE Install the No.2 fuel pipe with the 2 union bolts and 4 gaskets. Torque: 32.5 N–m (330 kgf–cm, 24 ft–lbf) 16. INSTALL NO.1 FUEL PIPE AND PULSATION DAMPER Install the No.1 fuel pipe with the pulsation damper, 4 new gaskets and bolt. Torque: 32.5 N–m (330 kgf–cm, 24 ft–lbf) for Pulsation damper Torque: 15 N–m (150 kgf–cm, 11 ft–lbf) for Bolt EG2–108 1MZ–FE ENGINE – ENGINE MECHANICAL 17. INSTALL TVV (a) Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833–00070, THREE BOND 1324 or equivalent (b) Install the TVV. Torque: 30 N–m (305 kgf–cm, 22 ft–lbf) 18. INSTALL FUEL PRESSURE REGULATOR (a) Apply a light coat of gasoline to a new 0–ring, and install it to the pressure regulator. (b) Attach the pressure regulator to the delivery pipe. (c) Check that the pressure regulator rotates smoothly. NOTICE: If it does not rotate smoothly, the O–ring may be pinched, so remove the pressure regulator and repeat steps (b) and (e) above. EG2–109 1MZ–FE ENGINE – ENGINE MECHANICAL (d) Install the pressure regulator with the 2 bolts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) 19. INSTALL INTAKE MANIFOLD Install the intake manifold with the 9 bolts, 2 nuts and 2 plate washers. Torque: 15 N–m (150 kgf–cm, 11 ft–lbf) 20. RETIGHTEN WATER OUTLET MOUNTING BOLTS AND NUTS Torque: 15 N–m (150 kgf–cm, 11 ft–lbf) 21. INSTALL AIR ASSIST HOSE 22. INSTALL WATER INLET PIPE (a) Install a new O–ring to the water inlet pipe. (b) Apply soapy water to the O–ring. EG2–110 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Connect the water inlet pipe to the water inlet. (d) Install the bolt holding the water inlet pipe to the cylinder head. Torque: 19.5 N–m (200 kgf–cm, 14 ft–lbf) 23. INSTALL CYLINDER HEAD REAR PLATE (a) Install the rear plate and grand strap with the bolt and nut. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) (b) Connect the vacuum hose to the air intake chamber. (c) Connect the 2 vacuum hoses to the vacuum tank. 24. INSTALL NO–3 TIMING BELT COVER (a) Check that the timing belt cover gaskets have no cracks or peeling, etc. If the gaskets do have cracks or peeling etc., replace them using following steps. (1) Using a screwdriver and gasket scraper, remove all the old gasket material. (2) Thoroughly clean all components to remove all the loose material. (3) Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded black in the illustration. NOTICE: When joining gaskets, do not leave a gap be– tween them. Cut off any excess gasket. (4) After installing the gasket, press down on it so that the adhesive firmly sticks to the belt cover. (b) Install new gaskets to the No.3 belt cover. (c) Install the belt cover with the 6 bolts. Torque: 8.5 N–m (85 kgf–cm, 74 in–lbf) EG2–111 1MZ–FE ENGINE – ENGINE MECHANICAL 25. INSTALL NO.2 IDLER PULLEY (a) Install the idler pulley with the bolt. Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) (b) Check that the idler pulley moves smoothly. 26. INSTALL RH CAMSHAFT TIMING PULLEY (a) Install the timing pulley, facing the flange side out– ward. (b) Align the knock pin hole of the camshaft with the knock pin groove of the timing pulley as shown. (c) Using SST, install and torque the bolt. SST 09249–63010, 09960–10010 (09962–01000) Torque: 88 N–m (900 kgf–cm, 65 ft–lbf) HINT: Use a torque wrench with a fulcrum length of 340 mm (13.39 in.) 27. INSTALL LH CAMSHAFT TIMING PULLEY (a) Install the timing pulley, facing the flange side inward. (b) Align the knock pin hole of the camshaft with the knock pin groove of the timing pulley as shown. (d) Using SST, install and torque the bolt. SST 09960–10010 (09962–01000) Torque: 125 N–m (1,300 kgf–cm, 94 ft–lbf) EG2–112 1MZ–FE ENGINE – ENGINE MECHANICAL 28. INSTALL TIMING BELT (See steps 6 to 27 on pages EG2–51 to 66) 29. INSTALL FRONT EXHAUST PIPE (a) Temporarily install 3 new gaskets and the front ex– haust pipe with the 2 bolts and 6 nuts. (b) Tighten the 4 nuts holding the exhaust manifolds to the front exhaust pipe. Torque: 62 N–m (630 kgf–cm, 46 ft–lbf) (c) Tighten the 2 bolts and 2 nuts holding the three–way catalytic converter to the front exhaust pipe. Torque: 56 N–m (570 kgf–cm, 41 ft–lbf) (d) Connect the bracket with the 2 bolts. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) (e) Connect the front exhaust pipe clamp with the 2 bolts. Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) 30. INSTALL SPARK PLUGS Using a 16 mm plug wrench, install the6 spark plugs to the RH and LH cylinder heads. 31. INSTALL IGNITION COILS Install the6 ignition coils to the RH and LH cylinder heads. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) EG2–113 1MZ–FE ENGINE – ENGINE MECHANICAL 32. CONNECT ENGINE WIRE TO ENGINE RH SIDE (a) Connect the following connectors: (1) 3 injector connectors (2) 3 ignition coil connectors (3) Water temperature sender gauge connector (4) Water temperature sensor connector (5) RH oxygens sensor connector (b) Connect the engine wire with the 5 nuts. 33. CONNECT ENGINE WIRE TO ENGINE REAR SIDE (a) Connect the following connectors: (1) LH oxygen sensor (2) Engine coolant temperature sensor (3) Camshaft position sensor (b) Connect the 3 clamps. (c) Connect the engine wire with the 2 nuts. 34. CONNECT ENGINE WIRE TO N0.3 TIMING BELT COVER Connect the engine wire with the 2 clamps. EG2–114 1MZ–FE ENGINE – ENGINE MECHANICAL 35. CONNECT ENGINE WIRE TO ENGINE LH SIDE (a) Connect the following connectors: (1) 3 injector connectors (2) 3 ignition coil connectors (b) Connect the engine wire with the 2 nuts. 36. INSTALL EGR VALVE AND VACUUM MODULATOR TO AIR INTAKE CHAMBER Install a new gasket, the EGR valve and vacuum mod– ulator with the 3 nuts. Torque: 12 N–m (120 kgf–cm, 9 ft–lbf) 37. INSTALL THROTTLE BODY TO AIR INTAKE CHAMBER (a) Place a new gasket on the air intake chamber. (b) Install the throttle body with the 2 bolts and 2 nuts. Torque: 19.5 N–m (200 kgf–cm. 14 ft–lbf) (c) Connect the following vacuum hoses: (1) Vacuum hose to P port of EGR vacuum modula– tor (2) Vacuum hose to R port of EGR vacuum modula– tor 38. INSTALL A/C IDLE–UP VSV TO AIR INTAKE CHAMBER (a) Install the A/C idle–up VSV with the 2 bolts. (b) Connect the air hose. EG2–115 1MZ–FE ENGINE – ENGINE MECHANICAL 39. INSTALL INTAKE AIR CONTROL VALVE TO AIR INTAKE CHAMBER (a) Install a new gasket to the air intake chamber. (b) Apply a light coat of engine oil to the rubber portions. (c) Apply seal packing to the positions of the intake air control valve as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent (d) Install the intake air control valve and data link con– nector 1 clamp with the 3 nuts. Torque: 14.5 N–m (145 kgf–cm, 10 ft–lbf) (d) Connect the A/C air hose. 40. INSTALL AIR INTAKE CHAMBER (a) Using an 8 mm hexagon wrench, install a new gasket and the air intake chamber with the 2 bolts and 2 nuts. Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) (b) Connect the following hoses: (1) 2 water bypass hoses (2) Air assist hose (c) Connect the following vacuum hoses: (1) 2 vacuum hoses to TVV (2) Vacuum hose to cylinder head rear plate EG2–116 1MZ–FE ENGINE – FE ENGINE – ENGINE MECHANICAL (3) Vacuum hose to charcoal canister (d) Connect the following connectors: (1) Throttle position sensor connector (2) IAC valve connector (3) EGR gas temperature sensor connector (4) A/C idle–up connector (e) Install 2 new gaskets and EGR pipe with the 4 nuts. Torque: 12 N–m (120 kgf–cm, 9 ft–lbf) (f) Install the No.1 engine hanger with the 2 bolts. Torque: 39 N–m (400 kgf–cm, 19 ft–lbf) (g) Install the air intake chamber stay with the 2 bolts. Torque: 19.5 N–m (200 kgf–cm, 14 ft–lbf) (h) Connect the 2 PS air hoses. (i) Connect the PS pressure tube with the 2 nuts. EG2–117 1MZ–FE ENGINE – ENGINE MECHANICAL (j) Connect the RH oxygen sensor connector clamp to the PS pressure tube. (k) Connect the ground strap with the bolt. (1) Connect the hydraulic pressure pipe to the air intake chamber with the bolt. (m) Connect the following hoses: (1) Brake booster vacuum hose (2) PCV hose (3) Intake air control valve vacuum hose (n) Connect the data link connector 1. (o) Connect the 2 ground straps with the nut. Torque: 14.5 N–m (145 kgf–cm, 10 ft–lbf) 41. INSTALL EMISSION CONTROL VALVE SET (a) Install the emission control valve set with the 2 bolts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) (b) Connect the following connectors: (1) Intake air control connector (2) Fuel pressure connector (3) EGR VSV connector EG2–118 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Connect the following vacuum hoses: (1) Vacuum hose to fuel pressure control VSV (2) Vacuum hose to fuel pressure regulator (3) Vacuum hose to cylinder head rear plate (4) Vacuum hose to intake air control valve VSV (5) Vacuum hose to EGR vacuum modulator (6) Vacuum hose to EGR valve 42. INSTALL V–BANK COVER Using a 5 mm hexagon wrench, install the V–bank cover with the 2 nuts. 43. CONNECT PRESSURE HOSE TO HYDRAULIC MOTOR Connect the pressure hose to the water inlet. 44. CONNECT FUEL HOSES (a) Connect the fuel return hose to the fuel pipe. (b) Connect the fuel inlet hose to the fuel filter. Torque: 30 N–m (300 kgf–cm, 22 ft–lbf) 45. CONNECT HEATER HOSES Connect the 2 hoses. EG2–119 1MZ–FE ENGINE – ENGINE MECHANICAL 46. CONNECT RADIATOR HOSES Connect the 2 hoses. 47. INSTALL RH ENGINE MOUNTING STAY Install the mounting stay with the 3 bolts. Torque: 31.4 N–m (320 kgf–cm, 23 ft–lbf) 48. CONNECT GROUND STRAPS Connect the 2 straps. 49. w/ CRUISE CONTROL SYSTEM: INSTALL CRUISE CONTROL ACTUATOR (a) Connect the actuator and bracket with the 3 bolts. (b) Connect the actuator connector and clamp. (c) Install the actuator cover with the bolt and clip. 50. INSTALL AIR CLEANER CAP, VOLUME AIR FLOW METER AND AIR CLEANER HOSE (a) Connect the air cleaner hose, and install the air clean– er cap and volume air flow meter with the 4 clips. (b) Tighten the air cleaner hose clamp bolt. (c) Connect the PCV hose. (d) Connect the accelerator cable clamp. (e) Connect the volume air flow meter connector and wire clamp. EG2–120 1MZ–FE ENGINE – ENGINE MECHANICAL 51. CONNECT THROTTLE CABLE 52. CONNECT ACCELERATOR CABLE 53. FILL WITH ENGINE COOLANT Capacity: 8.7 liters (9.2 US qts, 7.7 Imp. qts) 54. INSTALL BATTERY TRAY AND BATTERY 55. START ENGINE AND CHECK FOR LEAKS 56. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 57. RECHECK ENGINE COOLANT LEVEL EG2–121 1MZ–FE ENGINE – ENGINE MECHANICAL CYLINDER BLOCK COMPONENTS FOR ENGINE REMOVAL AND INSTALLATION EG2–122 1MZ–FE ENGINE – ENGINE MECHANICAL EG2–123 1MZ–FE ENGINE – ENGINE MECHANICAL EG2–124 1MZ–FE ENGINE – ENGINE MECHANICAL ENGINE REMOVAL (See Components for Engine Removal and Installation) 1. REMOVE BATTERY AND TRAY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE HOOD 3. DRAIN ENGINE COOLANT 4. DRAIN ENGINE OIL 5. DISCONNECT ACCELERATOR CABLE 6. DISCONNECT THROTTLE CABLE 7. REMOVE AIR CLEANER CAP, VOLUME AIR FLOW METER AND AIR CLEANER HOSE (a) Disconnect the volume air flow meter connector and wire clamp. (b) Disconnect the accelerator cable clamp. (c) Disconnect the PCV hose. (d) Loosen the air cleaner hose clamp bolt. (e) Disconnect the 4 air cleaner cap clips. (f) Remove the air cleaner cap and volume air flow meter together with the air cleaner hose. (g) Remove the element. (h) Remove the 3 bolts and air cleaner case. 8. w/ CRUISE CONTROL SYSTEM: REMOVE CRUISE CONTROL ACTUATOR (a) Remove the bolt, clip and actuator cover. (b) Disconnect the actuator connector and clamp. (c) Remove the 3 bolts, and disconnect the actuator with the bracket. EG2–125 1MZ–FE ENGINE – ENGINE MECHANICAL 9. REMOVE RADIATOR (See page EG2–336) 10. DISCONNECT ENGINE WIRE (a) Remove the 2 bolts and disconnect the engine relay box. (b) Disconnect the following wires and connectors: (1) 5 connectors from relay box (2) 2 igniter connectors (3) Noise filter connector (4) Connector from LH fender apron (5) 2 ground straps (c) Disconnect the wire clamp. (d) Disconnect the connector from the LH fender apron. (e) Remove the bolt and disconnect the ground strap. (f) Disconnect the wire clamp. 11. DISCONNECT VACUUM HOSES Disconnect the following vacuum hoses: (1) Vacuum hoses from vacuum tank for intake air control valve EG2–126 1MZ–FE ENGINE – FE ENGINE – ENGINE MECHANICAL (2) Vacuum hose from charcoal canister (3) Brake booster vacuum hose from air intake cha– mber 12. DISCONNECT HEATER HOSES Disconnect the 2 hoses. 13. DISCONNECT FUEL HOSES Disconnect the fuel inlet and return hoses. CAUTION: Catch leaking fuel in a container. 14. DISCONNECT TRANSAXLE CONTROL CABLE FROM TRANSAXLE EG2–127 1MZ–FE ENGINE – ENGINE MECHANICAL 15. DISCONNECT ENGINE WIRE FROM CABIN (a) Remove the following parts: (1) Under cover (2) Lower instrument panel (3) Glove compartment door (4) Glove compartment (b) Disconnect the following connectors: (1) 3 ECM connectors (2) 5 cowl wire connectors (3) Cooling fan ECU connector (c) Disconnect the wire clamp. (d) Remove the 2 nuts, and pull out the engine wire from the cowl panel. 16. REMOVE A/C COMPRESSOR WITHOUT DISCONNECTING HOSES (a) Disconnect the A/C compressor connector. (b) Remove the drive belt. (c) Remove the 5 bolts and drive belt adjusting bar brack– et and, disconnect the A/C compressor. HINT: Move the compressor aside and suspend it. EG2–128 1MZ–FE ENGINE – ENGINE MECHANICAL 17. REMOVE FRONT EXHAUST PIPE (a) Remove the 2 bolts and exhaust pipe clamp. (b) Remove the 2 bolts, and disconnect the bracket. (c) Remove the 2 bolts and 2 nuts holding the front exhaust pipe to the three–way catalytic converter. (d) Remove the 4 nuts holding the front exhaust pipe to the exhaust manifolds. (e) Remove the front exhaust pipe and 3 gaskets. 18. REMOVE DRIVE SHAFTS (See SA section) 19. DISCONNECT PS PRESSURE TUBE (a) Disconnect the 2 PS air hoses. (b) Remove the 2 nuts and disconnect the PS pressure tube. 20. DISCONNECT HYDRAULIC COOLING FAN PRESSURE HOSE Using SST, disconnect the pressure hose. SST 09631– 22020 21. REMOVE PS PUMP WITHOUT DISCONNECTING HOSES (a) Remove the PS drive belt. (b) Remove the 2 bolts, and disconnect the PS pump from the engine. HINT: Move the PS pump aside and suspend it. EG2–129 1MZ–FE ENGINE – ENGINE MECHANICAL 22. DISCONNECT LH ENGINE MOUNTING INSULATOR Remove the 4 bolts, and disconnect the mounting insulator. 23. DISCONNECT RR ENGINE MOUNTING INSULATOR (a) Remove the 2 hole plugs. (b) Remove the 4 nuts, and disconnect the mounting insulator. 24. REMOVE ENGINE MOUNTING SHOCK ABSORBER Remove the 4 bolts and engine mounting shock ab– sorber. 25. DISCONNECT FR ENGINE MOUNTING INSULATOR Remove the 3 bolts, and disconnect the mounting insulator. 26. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS EG2–130 1MZ–FE ENGINE – ENGINE MECHANICAL 27. REMOVE COOLANT RESERVOIR TANK (a) Disconnect the reservoir hose. (b) Using a screwdriver, remove the reservoir tank. 28. DISCONNECT GROUND STRAPS Disconnect the 2 straps. 29. REMOVE RH ENGINE MOUNTING STAY Remove the 3 bolts and RH engine mounting stay. 30. REMOVE ENGINE MOVING CONTROL ROD AND NO.2 RH ENGINE MOUNTING BRACKET Remove the 3 bolts, control rod and mounting brack– et. EG2–131 1MZ–FE ENGINE – ENGINE MECHANICAL 31. REMOVE ENGINE AND TRANSAXLE ASSEMBLY PROM VEHICLE (a) Lift the engine out of the vehicle slowly and carefully. NOTICE: Be careful not to hit the PS gear housing or park/neutral position switch. (b) Make sure the engine is clear of all wiring, hoses and cables. (c) Place the engine and transaxle assembly onto the stand. 32. REMOVE FR ENGINE MOUNTING INSULATOR Remove the 4 bolts and mounting insulator. 33. REMOVE RR ENGINE MOUNTING INSULATOR Remove the 4 bolts and mounting insulator. 34. REMOVE FRONT EXHAUST PIPE STAY Remove the 2 bolts and pipe stay. EG2–132 1MZ–FE ENGINE – ENGINE MECHANICAL COMPONENTS FOR ENGINE & TRANSAXLE SEPARATION AND ASSEMBLY ENGINE & TRANSAXLE SEPARATION (See Components for Engine & Transaxle Separation and Assembly) 1. DISCONNECT ENGINE WIRE (a) Disconnect the following connector: (1) O/D solenoid connector (2) PNP switch speedometer (3) Starter 50 terminal (4) Starter B terminal (5) Speed sensor connector (b) Disconnect the 2 wire clamps from the transaxle. EG2–133 1MZ–FE ENGINE – ENGINE MECHANICAL 2. REMOVE OIL DIPSTICK GUIDE AND DIPSTICK FOR TRANSAXLE (a) Remove the mounting bolt. (b) Pull out the dipstick guide and dipstick from the port of transaxle. (c) Remove the 0–ring from the dipstick guide. 3. REMOVE STARTER Remove the 2 bolts and starter. 4. REMOVE TRANSAXLE A. Remove torque converter clutch mounting bolts (a) Remove the 2 bolts and flywheel housing undercover. (b) Turn the crankshaft pulley bolt to gain access to each bolt. (c) Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts. 6. Remove transaxle (a) Remove the bolt, 2 nuts, manifold stay and exhaust manifold plate. EG2–134 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Remove the bolt, nut and No.2 manifold stay. (c) Remove the 2 bolts holding the No.2 oil pan to the transaxle. (d) Remove the 6 bolts holding the engine to the trans– axle. (e) Remove the transaxle together with the torque con– verter clutch from the engine. 5. REMOVE DRIVE PLATE Uniformly loosen and remove the drive plate bolts, in several passes, in the sequence shown. EG2–135 1MZ–FE ENGINE – ENGINE MECHANICAL COMPONENTS FOR PREPARATION AND AFTER ASSEMBLY EG2–136 1MZ–FE ENGINE – FE ENGINE – ENGINE MECHANICAL PREPARATION FOR DISASSEMBLY (See Components for Cylinder Block Preparation of Disassembly and After Assembly) 1. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 2. REMOVE TIMING BELT AND PULLEYS (See pages EG2–42 to 47) 3. REMOVE CYLINDER HEAD (See pages EG2–64 to 79) 4. REMOVE GENERATOR Remove the 2 bolts and generator. 5. REMOVE GENERATOR ADJUSTING BAR AND BRACKET Remove the 3 nuts, generator adjusting bar and bra– cket. 6. REMOVE A/C COMPRESSOR HOUSING BRACKET Remove the 3 bolts and compressor housing bracket. 7. REMOVE No.2 IDLER PULLEY BRACKET Remove the 2 bolts and idler pulley bracket. EG2–137 1MZ–FE ENGINE – ENGINE MECHANICAL 8. REMOVE KNOCK SENSORS (a) Disconnect the 2 knock sensor connectors. (b) Remove the wire band. (c) Disconnect the engine wire clamp. (d) Using SST, remove the 2 knock sensors. SST 09816 – 30010 9. REMOVE WATER INLET HOUSING Remove the 8 bolts, 2 nuts and water inlet housing. 10. REMOVE WATER PUMP Remove the 4 bolts, 2 nuts, water pump and gasket. 11. REMOVE NO.2 OIL PAN (a) Remove the 10 bolts and 2 nuts. EG2–138 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Insert the blade of SST between the No. 1 and No.2 oil pans, and cut off applied sealer and remove the No. 1 oil pan. SST 09032 – 00100 NOTICE: • Be careful not to the damage the No.2 oil pan con– tact surface of the No.1 oil pan. • Be careful not to damage the No.2 oil pan flange. 12. REMOVE OIL STRAINER Remove the bolt, 2 nuts, oil strainer and gasket. 13. REMOVE NO.1 OIL PAN (a) Remove the 17 bolts. (b) Using a screwdriver, remove the No. 1 oil pan by prying the portions between the cylinder block and No.1 oil pan. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and No.1 oil pan. EG2–139 1MZ–FE ENGINE – ENGINE MECHANICAL 14. REMOVE OIL PUMP (a) Remove the 9 bolts. (b) Remove the oil pump by prying a screwdriver between the oil pump and main bearing cap. (c) Remove the 0–ring. 15. REMOVE OIL FILTER Using SST, remove the oil filter. SST 09816 – 30010 16. REMOVE OIL FILTER UNION Using a 12 mm hexagon wrench, remove the oil filter union. 17. REMOVE WATER SEAL PLATE Remove the 2 nuts and seal plate. EG2–140 1MZ–FE ENGINE – ENGINE MECHANICAL 18. REMOVE ENGINE COOLANT DRAIN COCK 19. REMOVE OIL PRESSURE SWITCH Using SST, remove the oil pressure switch. SST 09816 – 30010 20. REMOVE EGR COOLER Remove the 3 bolts, 2 nuts, EGR cooler and gasket. EG2–141 1MZ–FE ENGINE – ENGINE MECHANICAL COMPONENTS FOR CYLINDER BLOCK DISASSEMBLY AND ASSEMBLY EG2–142 1MZ–FE ENGINE – ENGINE MECHANICAL CYLINDER BLOCK DISASSEMBLY (See Components for Disassembly and Assembly) 1. REMOVE REAR OIL SEAL RETAINER (a) Remove the 6 bolts. (b) Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and main bearing cap. 2. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back an forth. Standard thrust clearance: 0.15 – 0.30 mm (0.0059 – 0.0118 in.) Maximum thrust clearance: 0.35 mm (0.0138 in.) If the thrust clearance is greater than maximum, re– place the connecting rod assembly (s). If necessary, replace the crankshaft. Connecting rod thickness: 20.80 – 20.85 mm (0.8189 – 0.8209 in.) 3. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE (a) Check the matchmarks on the connecting rod and cap to ensure correct reassembly. (b) Remove the 2 connecting rod cap bolts. EG2–143 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Using the 2 removed connecting rod cap bolts, remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left. HINT: Keep the lower bearing inserted with the con– necting rod cap. (d) Clean the crank pin and bearing. (e) Check the crank pin and bearing for pitting and scrat– ches. If the crank pin or bearing is damaged, replace the bearings. If necessary, replace the crankshaft. (f) Lay a strip of Plastigage across the crank pin. (g) Install the connecting rod cap with the 2 bolts. (See step 7 on page EG2–167) Torque: 1st 24.5 N–m (250 kgf–cm. 18 ft–lbf) 2nd Turn extra 90
NOTICE: Do not turn the crankshaft. (h) Remove the 2 bolts, connecting rod cap and lower bearing. (See procedure (b) and (c) above) EG2–144 1MZ–FE ENGINE – ENGINE MECHANICAL Measure the Plastigage at its widest point. Standard oil clearance: 0.038 – 0.064 mm (0.0015 – 0.0025 in.) Maximum oil clearance: 0.08 mm (0.0031 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crank– shaft. HINT: If replacing a bearing, replace it with 1 having the same number as marked on the connecting rod. There are 4 sizes of standard bearings, marked ”I”, ”2”, ”3” and ”4” accordingly. Reference: Connecting rod big end inside diameter: Mark ’1” 518.000 – 56.006 mm (2.2047 – 2.2050 in.) Mark ’2’ 56.006 – 56.012 mm (2.2050 – 2.2052 in.) Mark ’3’ 56.012 – 56.018 mm (2.2052 – 2.2054 in.) Mark ”4’ 56.018 – 56.024 mm (2.2054 – 2.2057 in.) Crankshaft crank pin diameter: 52.994 – 53.000 mm (2.0864 – 2.0868 in.) Standard sized bearing center wall thickness: Mark ’1’ 1.484 – 1.487 mm (0.0584 – 0.0585 in.) Mark ’2’ 1.487 – 1.490 mm (0.0585 – 0.0587 in.) Mark ’3’ 1.490 – 1.493 mm (0.0587 – 0.0588 in.) Mark W 1.493 – 1.496 mm (0.0588 – 0.0589 in.) (j) Completely remove the Plastigage. 4. REMOVE PISTON AND CONNECTING ROD ASSEMBLIES (a) Using a ridge reamer, remove all the carbon from the top of the cylinder. (b) Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. EG2–145 1MZ–FE ENGINE – ENGINE MECHANICAL HINT: • Keep the bearings, connecting rod and cap to– gether. • Arrange the piston and connecting rod assembl– ies in correct order. 5. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 – 0.24 mm (0.0016 – 0.0095 In.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, re– place the thrust washers as a set. Thrust washer thickness: 1.930 – 1.980 mm (0.0760 – 0.0780 In.) 6. REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE (a) Uniformly loosen and remove the 8 main bearing cap bolts and seal washers, in several passes, in the se– quence shown. EG2–146 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Uniformly loosen and remove the 16 main bearing cap bolts, in several passes, in the sequence shown. (c) Using a screwdriver, pry out main bearing caps, remove the 4 main bearing caps, lower bearings and (No.2 main bearing cap only) 2 lower thrust washers. HINT: • Keep the lower bearing and main bearing cap together. • Arrange the main bearing caps and lower thrust washers in correct order. (d) Lift out the crankshaft. HINT: Keep the upper bearings together with the cyl– inder block. (e) Clean each main journal and bearing. (f) Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bear– ings. If necessary, replace the crankshaft. (g) Place the crankshaft on the cylinder block. (h) Lay a strip of Plastigage across each journal. EG2–147 1MZ–FE ENGINE – ENGINE MECHANICAL (i) Install the 4 main bearing caps. (See step 4 on pages EG2–165) 12 Pointed Head Bolts: Torque: 1 st 22 N–m (225 kgf–cm, 16 ft–lbf) 2nd Turn extra 90
Hexagon Head Bolts: Torque: 27 N–m (275 kgf–cm, 20 ft–lbf) NOTICE: Do not turn the crankshaft. (j) Remove the main bearing caps. (See procedures (a) to (c) above) (k) Measure the Plastigage at its widest point. Standard oil clearance: 0.026 – 0.046 mm (0.0010 – 0.0018 in.) Maximum clearance: 0.06 mm (0.0024 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, replace the crankshaft. HINT: If using a bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding to– gether the numbers imprinted on the cylinder block and crankshaft, then refer to the table below for the appropriate bearing number. There are 5 standard bearing sizes, marked ’1’, ”2”, ”3”, ”4” and ”5” accord– ingly. ” ”: Number mark Total number Cylinder block (A) + Crankshaft ( B ) _ Use bearing 0–5 6–11 “1” “2” 12–17 18–23 24–28 “4” ”5” EXAMPLE: Cylinder block ”06” (A) + Crankshaft ”08” (B) = Total number 14 (Use bearing ”3”) EG2–148 1MZ–FE ENGINE – ENGINE MECHANICAL Reference: Cylinder block main journal bore diameter (A): Mark ”00’ 66.000 mm (2.5984 in.) Mark ’01’ 66.001 mm (2.5985 in.) Mark ”02” 66.002 mm (2.5985 in.) Mark ’03’ 66.003 mm (2.5985 in.) Mark ”04’ 66.004 mm (2.5986 in.) Mark ’05’ 66.005 mm (2.5986 In.) Mark ’06’ 66.006 mm (2.5987 in.) Mark ’07’ 66.007 mm (2.5987 in.) Mark ’08’ 66.008 mm (2.5987 in.) Mark ’09’ 66.009 mm (2.5988 in.) Mark ”10’ 66.010 mm (2.5988 in.) Mark ’11 ” 66.011 mm (2.5989 in.) Mark ’12’ 66.012 mm (2.5989 in.) Mark ’13’ 66.013 mm (2.5989 in.) Mark ”14’ 66.014 mm (2.5990 in.) Mark ’15’ 66.015 mm (2.5990 in.) Mark ”16’ 66.01 6 mm (2.5990 in.) EG2–149 1MZ–FE ENGINE – ENGINE MECHANICAL Crankshaft main journal diameter (B): Mark ’00” 61.000 mm (2.401 6 in.) Mark ”01’ 60.999 mm (2.4015 in.) Mark ’02’ 60.998 mm (2.4015 in.) Mark ”03” 60.997 mm (2.4015 in.) Mark ’04’ 60.996 mm (2.4014 in.) Mark ’05’ 60.995 mm (2.4014 in.) Mark ’06” 60.994 mm (2.4013 in.) Mark ’07’ 60.993 mm (2.4012 in.) Mark ’08’ 60.992 mm (2.4012 In.) Mark ’09” 60.991 mm (2.4012 In.) Mark ”10’ 60.990 mm (2.4012 in.) Mark ’11’ 60.989 mm (2.4011 in.) Mark ”12” 60.988 mm (2.4011 in.) Standard sized bearing center wall thickness: Mark ”1’ 2.488 – 2.489 mm (0.0979 – 0.0980 in.) Mark ”2 2.489 – 2.492 mm (0.0980 – 0.0981 in.) Mark ’3” 2.492 – 2.495 mm (0.0981 – 0.0982 in.) Mark ”4’ 2.495 – 2.498 mm (0.0982 – 0.0983 in.) Mark ”5’ 2.498 – 2.501 mm (0.0983 – 0.0985 in.) EG2–150 1MZ–FE ENGINE – ENGINE MECHANICAL Standard sized Bearing Selection Chart Crankshaft number mark Cylinder block number mark EXAMPLE: Cylinder block ”06”, Crankshaft ”08” = Use bearing ”3” (l) Completely remove the Plastigage. 7. REMOVE CRANKSHAFT (a) Lift out the crankshaft. (b) Remove the 4 upper main bearings and 2 upper thrust washers from the cylinder block. HINT: Arrange the main bearing caps, bearings and thrust washers in correct order. EG2–151 1MZ–FE ENGINE – ENGINE MECHANICAL CYLINDER BLOCK INSPECTION AND REPAIR 1. CLEAN CYLINDER BLOCK A. Remove gasket material Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. B. Clean cylinder block Using a soft brush and solvent, thoroughly clean the cylinder block. NOTICE: If the cylinder is washed at high temperatures, the cylinder liner sticks out beyond the cylinder block, so always wash the cylinder block at a temperature of 45
C (113
F) or less. 2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge, mea– sure the surface contacting the cylinder head gasket for warpage. Maximum warpage: 0.07 mm (0.0028 In.) If warpage is greater than maximum, replace the cylin– der block. 3. INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches. If deep scratches are present, replace the cylinder block. EG2–152 1MZ–FE ENGINE – FE ENGINE – ENGINE MECHANICAL 4. INSPECT CYLINDER BORE DIAMETER Using a cylinder gauge, measure the cylinder bore diameter at positions A, B and C in the thrust and axial directions. Standard diameter: 87.500 – 87.512 mm (3.4449 – 3.4453 in.) Maximum diameter: 87.52 mm (3.4457 in.) If the diameter is greater than maximum, replace the cylinder block. 5. REMOVE CYLINDER RIDGE If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder. 6. INSPECT MAIN BEARING CAP BOLTS (for 12 Pointed Head Bolts) Using a vernier caliper, measure the tension portion diameter of the main bearing cap bolt. Standard diameter: 7.500 – 7.600 mm (0.2953 – 0.2992 in.) Minimum diameter: 7.20 mm (0.2835 In.) If the diameter is less than minimum, replace the bolt. EG2–153 1MZ–FE ENGINE – ENGINE MECHANICAL PISTON AND CONNECTING ROD DISASSEMBLY 1. CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin. If any movement is felt, replace the piston and pin as a set. 2. REMOVE PISTON RINGS (a) Using a piston ring expander, remove the 2 compres– sion rings. (b) Remove the 2 side rails and oil ring by hand. HINT: Arrange the piston rings in correct order only. 3. DISCONNECT CONNECTING ROD FROM PISTON (a) Using a small screwdriver, pry out the 2 snap rings. (b) Gradually heat the piston to approx. 60
C (140
F). EG2–154 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Using a plastic–faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod. HINT: • The piston and pin are a matched set. • Arrange the pistons, pins, rings, connecting rods and bearings in correct order. PISTON AND CONNECTING ROD INSPECTION 1. CLEAN PISTON (a) Using a gasket scraper, remove the carbon from the piston top. (b) Using a groove cleaning tool or broken ring, clean the piston ring grooves. EG2–155 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Using solvent and a brush, thoroughly clean the piston. NOTICE: Do not use a wire brush. 2. INSPECT PISTON A. Inspect piston oil clearance (a) Using a micrometer, measure the piston diameter at ring angles to the piston pin center line, 23.2 mm (0.913 in.) from the piston head. Piston diameter: 87.406 – 87.416 mm (3.4412 – 3.4416 in.) (b) Measure the cylinder bore diameter in the thrust di– rections. (See step 4 on page EG2–152) (c) Subtract the piston diameter measurement from the cylinder bore diameter measurement. Standard oil clearance: 0.084 – 0.106 mm (0.0033 – 0.0042 in.) Maximum oil clearance: 0.13 mm (0.0051 in.) If the oil clearance is greater than maximum, replace all the6 pistons. If necessary, replace the cylinder block. HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with ”R”, the LH piston with ”L”. B. Inspect piston ring groove clearance Using a feeler gauge, measure the clearance between new piston ring and the wall of the ring groove. Ring groove clearance: No.1 0.020 – 0.070 mm (0.0008 – 0.0028 in.) No.2 0.020 – 0.060 mm (0.0008 – 0.0024 In.) If the clearance is not as specified, replace the piston. EG2–156 1MZ–FE ENGINE – FE ENGINE – ENGINE MECHANICAL C. Inspect piston ring end gap (a) Insert the piston ring into the cylinder bore. (b) Using a piston, push the piston ring a little beyond the bottom of the ring travel, 105 mm (4.13 in.) from the top of the cylinder block. (c) Using a feeler gauge, measure the end gap. Standard end gap: No. 1 0.25 – 0.35 mm (0.0098 – 0.0138 in.) No.2 0.35 – 0.45 mm (0.0138 – 0.0177 in.) Oil (Side rail) 0.15 – 0.40 mm (0.0059 – 0.0157 in.) Maximum end gap: No.1 0.95 mm (0.0374 in.) No.2 1.05 mm (0.0413 in.) Oil (Side rail) 1.00 mm (0.0394 in.) If the end gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, even with a new piston ring, replace the cylinder block. D. Inspect piston pin fit At 60
C (140
F), you should be able to push the piston pin into the piston pin hole with your thumb. 3. INSPECT CONNECTING ROD A. Inspect connecting rod alignment Using a rod aligner and feeler gauge, check the con– necting rod alignment. • Check for out–of–alignment. Maximum out–of –alignment: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If out–of–alignment is greater than maximum, re– place the connecting rod assembly. EG2–157 1MZ–FE ENGINE – ENGINE MECHANICAL • Check for twist Maximum twist: 0.15 mm (0.0059 in.) per 100 mm (3.94 in.) If twist is greater than maximum, replace the connect– ing rod assembly. B. Inspect piston pin oil clearance (a) Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 22.005 – 22.014 mm (0.8663 – 0.8667 in.) (b) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 21.997 – 22.006 mm (0.8660 – 0.8664 in.) (c) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.005 – 0.011 mm (0.0002 – 0.0004 in.) Maximum oil clearance: 0.05 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and piston pin as a set. C. If necessary, replace connecting rod bushing (a) Using SST and a press, press out the bushing. SST 09222 – 30010 EG2–158 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Align the oil holes of a new bushing and the connect– ing rod. (c) Using SST and a press, press in the bushing. SST 09222–30010 (d) Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (see step B above) between the bushing and piston pin. (e) Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb. D. Inspect connecting rod bolts Using a vernier caliper, measure the tension portion of of the connecting rod bolt. Standard diameter: 7.2 – 7.3 mm (0.284 – 0.287 in.) Minimum diameter: 7.0 mm (0.276 in.) HINT: If the tension portion diameter is less than minimum, replace the connecting rod bolt. EG2–159 1MZ–FE ENGINE – ENGINE MECHANICAL CRANKSHAFT INSPECTION 1. INSPECT CRANKSHAFT FOR CIRCLE RUNOUT (a) Place the crankshaft on V–blocks. (b) Using a dial indicator, measure the circle runout, as shown in the illustration. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the crankshaft. 2. INSPECT MAIN JOURNALS AND CRANK PINS (a) Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: 60.988 –61.000 mm (2.4011 – 2.4016 in.) Crank pin diameter: 52.994 – 53.000 mm (2.0864 – 2.0866 in.) If the diameter is not as specified, check the oil clear– ance (See steps 3 or6 on page EG2–142 or 145). If necessary, replace the crankshaft. (b) Check each main journal and crank pin for taper and out–of–round as shown. Maximum taper and out–of–round: 0.02 mm (0.0008 in.) If the taper and out–of–round is greater than maxi– mum, replace the crankshaft. EG2–160 1MZ–FE ENGINE – ENGINE MECHANICAL CRANKSHAFT OIL SEALS REPLACEMENT HINT: There are 2 methods (A and B) to replace the oil seal which are as follows: 1. REPLACE CRANKSHAFT FRONT OIL SEAL A. If oil pump is removed from cylinder block: (a) Using a screwdriver, pry out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge. SST 09223 – 00010 (c) Apply MP grease to the oil seal lip. B. If oil pump is installed to the cylinder block: (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. (c) Apply MP grease to a new oil seal lip. (d) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge. SST 09223 – 00010 EG2–161 1MZ–FE ENGINE – ENGINE MECHANICAL 2. REPLACE CRANKSHAFT REAR OIL SEAL A. If rear oil seal retainer is removed from cylinder block: (a) Using a screwdriver and hammer, tap out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223 –15030, 09608 – 30022 (09608 – 05010) (c) Apply MP grease to the oil seal lip. B. If rear oil seal retainer is installed to cylinder block: (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. (c) Apply MP grease to a new oil seal lip. (d) Using SST and a hammer, tap in the oil sea! until its surface is flush with the rear oil seal retainer edge. SST 09223–15030, 09608–30022 (09608–05010) EG2–162 1MZ–FE ENGINE – ENGINE MECHANICAL PISTON AND CONNECTING ROD ASSEMBLY 1. ASSEMBLE PISTON AND CONNECTING ROD (a) Using a small screwdriver, install a new snap ring at one end of the piston pin hole. HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. (b) Gradually heat the piston to about 60
C (140
F). (c) Coat the piston pin with engine oil. (d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. (e) Using a small screwdriver, install a new snap ring on the other end of the piston pin hole. HINT: Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston. EG2–163 1MZ–FE ENGINE – ENGINE MECHANICAL 2. INSTALL PISTON RINGS (a) Install the oil ring expander and 2 side rails by hand. (b) Using a piston ring expander, install the 2 compres– sion rings with the code mark facing upward. Code mark: No.1 1RorT No.2 2R or 2T (c) Position the piston rings so that the ring ends are as shown. NOTICE: Do not align the ring ends. 3. INSTALL BEARINGS (a) Align the bearing claw with the groove of the connect– ing rod or connecting cap. (b) Install the bearings in the connecting rod and con– necting rod cap. EG2–164 1MZ–FE ENGINE – FE ENGINE – ENGINE MECHANICAL CYLINDER BLOCK ASSEMBLY (See Components for Disassembly and Assembly) HINT: • Thoroughly clean all parts to be assembled. Before installing the parts, apply new engine oil to all sliding and and rotating surfaces. • Replace all gaskets, 0–rings and oil seals with new parts. 1. INSTALL MAIN BEARINGS HINT: • Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4 mm (0.882 in.) bearings in the No. 1 and No.4 cylinder block journal positions with the main bearing cap. • Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No.3 positions. • Upper bearings have an oil groove and oil holes; lower bearings do not. (a) Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings. NOTICE: Install the bearing with the oil hole in the cylin– der block. (b) Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings. HINT: A number is marked on each main bearing cap to indicate the installation position. 2. INSTALL UPPER THRUST WASHERS Install the 2 thrust washers under the No.2 journal position of the cylinder block with the oil grooves facing outward. EG2–165 1MZ–FE ENGINE – ENGINE MECHANICAL 3. PLACE CRANKSHAFT ON CYLINDER BLOCK 4. INSTALL MAIN BEARING CAPS AND LOWER THRUST WASHERS A. Place main bearing caps and lower thrust washers on cylinder block (a) Install the 2 thrust washers on the No.2 bearing cap with the grooves facing outward. (b) Temporarily place the 4 main bearing caps level and let them in their proper locations. (c) Apply a light coat of engine oil on the threads and under the main bearing cap bolts (12 Pointed Head Bolts). (d) Temporarily install the 8 main bearing cap bolts. (e) Using a plastic–faced hammer, lightly tap the bearing cap to ensure a proper fit. EG2–166 1MZ–FE ENGINE – ENGINE MECHANICAL B. Install main bearing cap bolts (for 12 Pointed Head Bolts) HINT: • The main bearing cap bolts are tightened in 2 progressive steps (steps (b) and (d)). • If any of the main bearing cap bolts is broken or deformed, replace it. (a) Apply a light coat of engine oil on the threads and under the main bearing cap bolts. (b) Install and uniformly tighten the 16 main bearing cap bolts, in several passes, in the sequence shown. Torque: 22 N–m (225 kgf–cm, 16 ft–lbf) If any of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt. (c) Mark the front of the main bearing cap bolts with paint. (d) Retighten the main bearing cap bolts by 90
in the numerical order shown. (e) Check that the painted mark is now at a 90
angle to the front. C. Install main bearing cap bolts (for Hexagon Head Bolts) (a) Install a new seal washer to the main bearing cap bolt. (b) Install and uniformly tighten the 8 main bearing cap bolts, in several passes, in the sequence shown. Torque: 27 N–m (275 kgf–cm, 20 ft–lbf) (c) Check that the crankshaft turns smoothly. EG2–167 1MZ–FE ENGINE – ENGINE MECHANICAL 5. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearance: 0.04 – 0.24 mm (0.0016 – 0.0095 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, re– place the thrust washers as a set. Thrust washer thickness: 1.930 – 1.980 mm (0.0760 – 0.0780 in.) 6. INSTALL PISTON AND CONNECTING ROD ASSEMBLES Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. HINT: The shape of the piston varies for the RH and LH banks. The RH piston is marked with ”R”, the LH piston with ”L”. 7. INSTALL CONNECTING ROD CAPS A. Place connecting rod cap on connecting rod (a) Match the numbered connecting rod cap with the connecting rod. (b) Align the pin dowels of the connecting rod cap with the pins of the connecting rod, and install the con– necting rod. EG2–168 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Check that the protrusion of the connecting rod cap is facing in the correct direction. B. Install connecting rod cap bolts HINT: • The connecting rod cap bolts are tightened in 2 progressive steps (steps (b) and (d)). • If any of the connecting rod cap bolts is broken or deformed, replace it. (a) Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts. (b) Install and alternately tighten the 2 connecting rod cap bolts in several passes. Torque: 24.5 N–m (250 kgf–cm, 18 ft–lbf) If any of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts. (c) Mark the front of the connecting cap bolts with paint. (d) Retighten the cap bolts by 90
as shown. (e) Check that the painted mark is now at a 90
angle to the front. (f) Check that the crankshaft turns smoothly. EG2–169 1MZ–FE ENGINE – ENGINE MECHANICAL 8. CHECK CONNECTING ROD OIL CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0.15 – 0.30 mm (0.0059 – 0.0118 in.) Maximum thrust clearance: 0.35 mm (0.0138 in.) If the thrust clearance is greater than maximum, re– place the connecting rod assembly (s). If necessary, replace the crankshaft. Connecting rod thickness: 20.80 – 20.85 mm (0.8189 – 0.8209 in.) 9. INSTALL REAR OIL SEAL RETAINER (a) Remove any old packing (FIPG) material and be care– ful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block. • Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves. • Thoroughly clean all components to remove all the loose material. • Using a non–residue solvent, clean both sealing surfaces. (b) Apply seal packing to the oil seal retainer as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent • Install a nozzle that has been cut to a 2 – 3 mm (0.08 – 0.12) opening. • Parts must be assembled within 3 minutes of application. Otherwise the material must be re– moved and reapplied. • Immediately remove nozzle from the tube and reinstall cap. EG2–170 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Install the oil seal retainer with the 6 bolts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) AFTER ASSEMBLY (See Components for Cylinder Block Preparation of Disassembly and After Assembly) 1. INSTALL EGR COOLER Install a new gasket and the EGR cooler with the 3 bolts and 2 nuts. Torque: 9 N–m (90 kgf–cm, 78 in.–lbf) 2. INSTALL OIL PRESSURE SWITCH (a) Apply adhesive to 2 or 3 threads. Adhesive: Part No. 08833–00080. THREE BOND 1344, LOCTITE 242 or equivalent (b) Using SST, install the oil pressure switch. SST 09816 – 30010 Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) 3. INSTALL ENGINE COOLANT DRAIN COCK (a) Apply seal packing to 2 or 3 threads. Seal packing: Part No. 08826–00100 or equivalent EG2–171 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Install the drain cock. Torque: 39 N–m (400 kgf–cm, 29 ft–lbf) HINT: After applying the specified torque, rotate the drain cock clockwise until it is in the position shown. 4. INSTALL WATER SEAL PLATE (a) Remove any old packing (FIPG) material and be care– ful not to drop any oil on the contact surfaces of the seal plate and cylinder block. • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. • Thoroughly clean all components to remove all the loose material. • Using a non–residue solvent, clean both sealing surfaces. (b) Apply seal packing to the seal plate as shown in the illustration. Seal packing: Part No. 08826–00100 or equivalent • Install a nozzle that has been cut to a 3–5 mm (0.12 – 0.20 in.) opening. • Parts must be assembled within 3 minutes of application. Otherwise the material must be re– moved and reapplied. • Immediately remove nozzle from the tube and reinstall cap. (c) Install the seal plate with the 2 nuts. Torque: 14.5 N–m (145 kgf–cm. 10 ft–lbf) EG2–172 1MZ–FE ENGINE – ENGINE MECHANICAL 5. INSTALL OIL FILTER UNION Using a 12 mm hexagon wrench, install the oil filter union. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) 6. INSTALL OIL FILTER (a) Apply clean engine oil to the gasket of anew oil filter. (b) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. (c) Using SST, tighten it an additional 3/4 turn. SST 09228–07500 7. INSTALL OIL PUMP (a) Remove any old packing (FIPG) material and be care– fuI not to drop any oil on the contact surfaces of the oil pump and cylinder block. • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. • Thoroughly clean all components to remove all the loose material. • Using a non–residue solvent, clean both sealing surfaces. EG2–173 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Apply seal packing to the oil pump as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent • Install a nozzle that has been cut to a 2–3 mm (0.08–0.12 in.) opening. HINT: Avoid applying an excessive amount to the surface. • Parts must be assembled within 3 minutes of application. Otherwise the material must be re– moved and reapplied. • Immediately remove nozzle from the tube and reinstall cap. (c) Place a new O–ring in position on the cylinder block. (d) Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft. (e) Install the oil pump with the 9 bolts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) for 10 mm head bolt 19.5 N–m (200 kgf–cm,14 ft–lbf) for 12 mm head bolt EG2–174 1MZ–FE ENGINE – ENGINE MECHANICAL 8. INSTALL N0.1 OIL PAN (a) Remove any old packing (FIPG) material and be care– ful not to drop any oil on the contact surface of the No.1 oil pan and cylinder block. • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. • Thoroughly clean all components to remove all the loose material. • Using a non–residue solvent, clean both sealing surfaces. NOTICE: Do not use a solvent which will affect the paint– ed surfaces. (b) Apply seal packing to the No.2 oil pan as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent Region ”x” is at the outer side of the bolt hole. Region ”*” is at the inner side of the bolt hole. • Install a nozzle that has been cut to a 4–5 m m (0.16 – 0.20 in.) opening. HINT: Avoid applying an excessive amount to the surface. • Parts must be assembled within 3 minutes of application. Otherwise the material must be re– moved and reapplied. • Immediately remove nozzle from the tube and reinstall cap. (c) Install the No.1 oil pan with the 17 bolts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) for 10 mm head bolt 19.5 N–m (200 kgf–cm, 14 ft–lbf) for 12 mm head bolt 9. INSTALL OIL STRAINER Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 8 N–m (80 kgf–cm, 69 in–lbf) EG2–175 1MZ–FE ENGINE – ENGINE MECHANICAL 10. INSTALL NO.2 OIL PAN (a) Remove any old packing (FIPG) material and be care– ful not to drop any oil on the contact surface of the No.1 and No.2 oil pans. • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. • Thoroughly clean all components to remove all the loose material. • Using a non–residue solvent, clean both sealing surfaces. NOTICE: Do not use a solvent which will affect the point– ed surfaces. (b) Apply seal packing to the No.2 oil pan as shown in the illustration. Seal packing: Part No. 08828–00080 or equivalent • Install a nozzle that–has been cut to a 4–5 mm (0.16 – 0.20 in.) opening. HINT: Avoid applying an excessive amount to the surface. • Parts must be assembled within 3 minutes of application. Otherwise the material must be re– moved and reapplied. • Immediately remove nozzle from the tube and reinstall cap. (c) Install the No.2 oil pan with the 10 bolts and 2 nuts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) 11. INSTALL WATER PUMP Install a new gasket and the water pump with the 4 bolts and 2 nuts. Torque: 8 N–m (80 kgf–cm, 69 in.–Ibf) NOTICE: Do not got oil on the gasket. EG2–176 1MZ–FE ENGINE – ENGINE MECHANICAL 12. INSTALL WATER INLET HOUSING (a) Remove any old packing (FIPG) material and be care– ful not to drop any oil on the contact surfaces of the water inlet housing and cylinder block. • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. • Thoroughly clean all components to remove all the loose material. • Using a non–residue solvent, clean both sealing surfaces. (b) Apply seal packing to the water inlet housing as shown in the illustration. Seal packing: Part No. 08826–00100 or equivalent • Install a nozzle that has been cut to a 3–5 mm (0.12–0.20 in.) opening. HINT: Avoid applying an excessive amount to the surface. • Parts must be assembled within 3 minutes of application. Otherwise the material must be re– moved and reapplied. • Immediately remove nozzle from the tube and reinstall cap. (c) Install the water inlet housing with the 8 bolts and 2 nuts, in the several passes, in the sequence shown. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) 13. INSTALL KNOCK SENSORS (a) Using SST, install the 2 knock sensors. SST 09816 – 30010 Torque: 39 N–m (400 kgf–cm, 29 ft–lbf) EG2–177 1MZ–FE ENGINE – ENGINE MECHANICAL (b) Connect the 2 knock sensor connectors. (c) Install the wire band. (d) Connect the engine wire clamp. 14. INSTALL NO.2 IDLER PULLEY BRACKET Install the pulley bracket with the 2 bolts. Torque: 28 N–m (290 kgf–cm, 21 ft–lbf) 15. INSTALL A/C COMPRESSOR HOUSING BRACKET Install the compressor housing bracket with the 3 bolts. Torque: 25 N–m (250 kgf–cm. 18 ft–lbf) 16. INSTALL GENERATOR BRACKET AND ADJUSTING BAR Install the generator bracket and adjusting bar with the 3 nuts. Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) 17. INSTALL GENERATOR Install the generator with the 2 bolts. Do not tighten the bolts yet. 18. INSTALL CYLINDER HEAD (See pages EG2–96 to 118) 19. INSTALL TIMING PULLEYS AND BELT (See pages EG2–49 to 55) 20. REMOVE ENGINE STAND EG2–178 1MZ–FE ENGINE – ENGINE MECHANICAL ENGINE & TRANSAXLE ASSEMBLY (See Components for Engine & Transaxle Separation and Assembly) 1. INSTALL DRIVE PLATE (a) Install the front spacer on the crankshaft with the chamfered end facing the shaft. (b) Install the drive pate and rear spacer on the crank– shaft. (c) Clean the threads of the bolt with the gasoline. (d) Apply adhesive to 2 or 3 threads of the mount bolt. Adhesive: Part No. 08833–00070. THREE BOND 1324 or equivalent (e) Install and uniformly tighten the mounting bolts, in the several passes, in the sequence shown. Torque: 83 N–m (850 kgf–cm, 61 ft–Ibf) 2. CHECK TORQUE CONVERTER CLUTCH INSTALLATION Using a scale and a straight edge, measure from the installed surface to the front surface of the transaxle housing. Correct distance: 13.7 mm (0.539 in.) or more EG2–179 1MZ–FE ENGINE – ENGINE MECHANICAL 3. INSTALL TRANSAXLE TO ENGINE A. Install transaxle (a) Attach the transaxle to the engine. (b) Install the6 bolts. Torque: 64 N–m (650 kgf–cm, 47 ft–lbf) (c) Install the 2 bolts holding the No.2 oil pan to the transaxle. Torque: 46 N–m (470 kgf–cm, 34 ft–lbf) (e) Install the No.2 manifold stay with the bolt and nut. Torque: 20 N–m (200 kgf–cm. 14 ft–lbf) (f) Install the manifold stay, exhaust manifold plate with the bolt and 2 nuts. Torque: 20 N–m (200 kgf–cm, 14 ft–lbf) HINT: Install the manifold so that the tip of the stay touches the head of the differential retainer installa– tion bolt as shown in the illustration. B. Install torque converter clutch mounting bolts (a) Clean the threads of the bolt with the gasoline. (b) Apply adhesive to 2 or 3 threads of the mount bolt. Adhesive: Part No. 08833–00070, THREE BOND 1324 or equivalent EG2–180 1MZ–FE ENGINE – ENGINE MECHANICAL (c) Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly. Torque: 41 N–m (420 kgf–cm, 30 ft–lbf) HINT: First install the dark green colored bolt, then install the other bolts. (d) Install the flywheel housing under cover with the 2 bolts. Torque: 18 N–m (185 kgf–cm, 13 ft–lbf) 4. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK FOR TRANSMISSION (a) Install a new 0–ring to the dipstick guide. (b) Apply soapy water to the 0 – ring. (c) Connect the dipstick guide end to the dipstick tube of the oil pan. (d) Install the dipstick guide with the bolt. (e) Install the dipstick. 5. CONNECT ENGINE WIRE (a) Connect the following parts: (1) O/D solenoid connector (2) PNP switch speedometer (3) Starter 50 terminal (4) Starter B terminal (5) Speed sensor connector (b) Disconnect the 2 wire clamps from the transaxle. (c) Install the 2 wire clamps to the transaxle. EG2–181 1MZ–FE ENGINE – ENGINE MECHANICAL 81 ENGINE INSTALLATION (See Components for Engine Removal and Installation) 1. INSTALL FRONT EXHAUST PIPE STAY Install the pipe stay with the 2 bolts. Torque: 21 N–m (210 kgf–cm, 16 ft–lbf) 2. INSTALL RR ENGINE MOUNTING INSULATOR Install the mounting insulator with the 4 bolts. Torque:63.7 N–m (650 kgf–cm, 47 ft–lbf) 3. INSTALL FR ENGINE MOUNTING INSULATOR Install the mounting insulator with the 4 bolts. Torque: 6.74 N–m (650 kgf–cm, 47 ft–lbf) 4. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE (a) Attach the engine sling device to the engine hangers. (b) Lower the engine into the engine compartment. Tilt the transaxle downward, lower the engine and clear the LH mounting. NOTICE: Be careful not to hit the PS gear housing or neutral start switch. (c) Keep the engine level, and align RH and LH mountings with the body bracket. EG2–182 1MZ–FE ENGINE – ENGINE MECHANICAL 5. INSTALL N0.2 ENGINE MOUNTING BRACKET AND ENGINE MOVING CONTROL ROD Install the engine moving control rod and No.2 engine mounting bracket with the 3 bolts. Torque: 63.7 N–m (650 kgf–cm, 47 ft–lbf) 6. INSTALL RH ENGINE MOUNTING STAY Install the RH mounting stay with the 3 bolts. Torque: 31.4 N–m (320 kgf–cm, 23 ft–Ibf) 7. CONNECT GROUND STRAPS Connect the 2 straps. 8. INSTALL COOLANT RESERVOIR TANK (a) Install the reservoir tank. (b) Connect the reservoir hose. 9. CONNECT FR ENGINE MOUNTING INSULATOR Connect the mounting insulator with the 3 bolts. Torque: 80.4 N–m (820 kgf–cm, 59 ft–lbf) for TMC made Torque: 65.7 N–m (670 kgf–cm, 48 ft–lbf) for TMM made EG2–183 1MZ–FE ENGINE – ENGINE MECHANICAL 10. INSTALL ENGINE MOUNTING ABSORBER Install the engine mounting absorber with the 4 bolts. Torque: 48 N–m (490 kgf–cm, 35 ft–lbf) 11. CONNECT RR ENGINE MOUNTING INSULATOR (a) Connect the mounting insulator with the 4 nuts. Torque: 65.7 N–m (670 kgf–cm, 48 ft–lbf) (b) Install the 2 hole plugs. 12. CONNECT LH ENGINE MOUNTING INSULATOR Connect the mounting insulator with the 4 bolts. Torque: 63.7 N–m (650 kgf–cm, 47 ft–lbf) 13. REMOVE ENGINE SLING DEVICE 14. INSTALL PS PUMP (a) Install the PS pump with the 2 bolts. Torque: 43 N–m (440 kgf–cm, 31 ft–lbf) (b) Install the drive belt. 15. CONNECT HYDRAULIC COOLING FAN PRESSURE HOSE Using SST, connect the pressure hose. SST 09631– 22020 Torque: 44 N–m (450 kgf–cm, 33 ft–lbf) EG2–184 1MZ–FE ENGINE – ENGINE MECHANICAL 16. CONNECT PS PRESSURE TUBE (a) Connect the PS pressure tube with the 2 nuts. (b) Connect the 2 PS air hoses. 17. INSTALL DRIVE SHAFTS (See SA section) 18. INSTALL FRONT EXHAUST PIPE (a) Temporarily install 3 new gaskets and the front ex– haust pipe with the 2 bolts and 6 nuts. (b) Tighten the 4 nuts holding the exhaust manifolds to the front exhaust pipe. Torque: 62 N–m (630 kgf–cm, 46 ft–lbf) (c) Tighten the 2 bolts and 2 nuts holding the three–way catalytic converter to the front exhaust pipe. Torque: 56 N–m (570 kgf–cm, 41 ft–lbf) (d) Connect the bracket with the 2 bolts. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) (e) Connect the front exhaust pipe clamp with the 2 bolts. Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) 19. INSTALL A/C COMPRESSOR (a) Install the A/C compressor and drive belt adjusting bar bracket with the 5 bolts. Torque: 25 N–m (250 kgf–cm, 18 ft–lbf) EG2–185 1MZ–FE ENGINE – ENGINE MECHANICAL 20. CONNECT ENGINE WIRE TO CABIN (a) Push in the engine wire through the cowl panel. Install the 2 nuts. (b) Connect the wire clamp. (c) Connect the following connectors: (1) 3 engine ECM connectors (2) 5 cowl wire connectors (3) Cooling fan ECU connector (d) Install the following parts: (1) Glove compartment (2) Glove compartment door (3) Lower instrument panel (4) Under cover 21. CONNECT TRANSAXLE CONTROL CABLE TO TRANSAXLE EG2–186 1MZ–FE ENGINE – ENGINE MECHANICAL 22. CONNECT FUEL HOSES (a) Connect the fuel return hose to the fuel pipe. (b) Connect the fuel inlet hose to the fuel filter. Torque: 30 N–m (300 kgf–cm, 22 ft–lbf) 23. CONNECT HEATER HOSES Connect the 2 hoses. 24. CONNECT VACUUM HOSES Connect the following vacuum hoses: (1) Brake booster vacuum hose to air intake chamber (2) Vacuum hose to charcoal canister (3) Vacuum hoses to vacuum tank for intake air control valve EG2–187 1MZ–FE ENGINE – ENGINE MECHANICAL 25. CONNECT ENGINE WIRE (a) Connect the wire clamps. (b) Connect the ground strap with the bolt. (c) Connect the connector to the LH fender apron. (d) Connect the wire clamps (e) Connect the following wires and connectors: (1) 2 igniter connectors (2) Noise filter connector (3) Connector to LH fender apron (4) 2 ground straps (5) 5 connectors to relay box (f) Connect the engine relay box with the 2 bolts. 26. INSTALL RADIATOR (See page EG2–342) 27. w/ CRUISE CONTROL SYSTEM: INSTALL CRUISE CONTROL ACTUATOR (a) Connect the actuator and bracket with the 3 bolts. (b) Connect the actuator connector and clamp. (c) Install the actuator cover with the bolt and clip. EG2–188 1MZ–FE ENGINE – ENGINE MECHANICAL 28. INSTALL AIR CLEANER CAP, VOLUME AIR FLOW METER AND AIR CLEANER HOSE (a) Connect the air cleaner hose, and install the air clean– er cap and volume air flow meter with the 4 clips. (b) Tighten the air cleaner hose clamp bolt. (c) Connect the PCV hose. (d) Connect the accelerator cable clamp. (e) Connect the volume air flow meter connector and wire clamp. 29. CONNECT THROTTLE CABLE 30. CONNECT ACCELERATOR CABLE 31. FILL ENGINE WITH OIL Capacity: Drain and refill w/ Oil filter change 4.7 liters (5.0 US qts, 4.1 Imp. qts) w/o Oil filter change 4.5 liters (4.8 US qts, 4.0 Imp. qts) Dry fill 5.5 liters (5.8 US qts, 4.8 Imp. qts) 32. FILL WITH ENGINE COOLANT Capacity: 8.7 liters (9.2 US qts, 7.7 Imp. qts) 33. INSTALL BATTERY TRAY AND BATTERY 34. START ENGINE AND CHECK FOR LEAKS 35. PERFORM ROAD TEST Check for abnormal noise, shock, slippage, correct shift points and smooth operation. 36. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS EG2–189 1MZ–FE ENGINE – ENGINE MECHANICAL EXHAUST SYSTEM COMPONENTS EG2–190 1MZ–FE ENGINE SERVICE SPECIFICATIONS SERVICE DATA Engine tune – up Intake manifold vacuum Compression pressure Tinning belt tensioner – – ENGINE MECHANICAL EG2–191 1MZ–FE ENGINE Cylinder head Valve guide bushing Valve Valve spring Valve lifter Camshaft Air intake chamber – ENGINE MECHANICAL EG2–192 1MZ–FE ENGINE Intake manifold Exhaust manifold Cylinder block Piston and piston ring Connecting rod – ENGINE MECHANICAL EG2–193 1MZ–FE ENGINE Connecting rod (Cont’d) Crankshaft TORQUE SPECIFICATIONS Part tightened Cylinder head cover x Cylinder head Spark plug x Cylinder head Ignition coil x Cylinder head cover Air intake chamber x Intake manifold EGR pipe x Exhaust manifold EGR pipe x Air intake chamber No.1 engine hanger x Air intake chamber No.1 engine hanger x Cylinder heed Air intake chamber stay x Air intake chamber Air intake chamber stay x Cylinder head Emission control valve set x Air intake chamber Timing belt plate x Oil pump No.1 idler pulley x Oil pump No.2 idler pulley x No.2 idler pulley bracket – ENGINE MECHANICAL EG2–194 1MZ–FE ENGINE Camshaft timing pulley x Camshaft (For use with SST) Camshaft timing pulley x Camshaft Timing belt tensioner x Oil pump Engine RH mounting bracket x Cylinder block No.2 timing belt cover x No.3 timing belt cover No.1 timing belt cover x Oil pump Crankshaft pulley x Crankshaft No.2 generator bracket x Engine RH mounting bracket Engine moving control rod x Engine RH mounting bracket Engine moving control rod x RH fender apron RH engine mounting stay x Water outlet RH engine mounting stay x Engine moving control rod RH engine mounting stay x No.2 RH engine mounting bracket Camshaft bearing cap x Cylinder head Cylinder head x Cylinder block – 12–pointed head bolt (1 st) Cylinder head x Cylinder block – 12–pointed head bolt (2nd) Cylinder head x Cylinder block – Recessed head bolt Camshaft position sensor x Cylinder head Exhaust manifold x Cylinder head EGR pipe x RH exhaust manifold EGR pipe x EGR cooler Exhaust manifold stay x Exhaust manifold Exhaust manifold stay x Transmission housing Oxygen sensor x Exhaust manifold PS bracket x RH cylinder head Oil dipstick guide x LH cylinder head No.2 engine hanger x LH cylinder head Water outlet x Intake manifold No.3 timing belt cover x Cylinder head Intake manifold x Cylinder head Delivery pipe x Intake manifold No. 1 fuel pipe x Intake manifold Cylinder head rear plate x LH cylinder head Water inlet pipe x LH cylinder head Front exhaust pipe x Exhaust manifold Front exhaust pipe x Three–way catalytic converter Front exhaust pipe bracket x Sub frame Front exhaust pipe clamp x Front exhaust pipe stay EGR valve x Air intake chamber Throttle body x Air intake chamber Intake air control valve x Air intake chamber Fuel inlet hose x Fuel filter Connecting rod cap x Connecting rod – 1 at Connecting rod cap x Connecting rod – 2nd Main bearing cap x Cylinder block – 1 st (12 pointed head bolt) Main bearing cap x Cylinder block – 2nd (12 pointed head bolt) Main bearing cap x Cylinder block (Hexagon head bolt) Rear oil seal retainer x Cylinder block EGR cooler x Cylinder block – ENGINE MECHANICAL EG2–195 1MZ–FE ENGINE Oil pressure switch x Cylinder block Engine coolant drain cock x Cylinder block Water seal plate x Cylinder block Oil filter union x Cylinder block Oil pump x Cylinder block (10 mm head bolt) Oil pump x Cylinder block (12 mm head bolt) No.1 oil pan x Cylinder block No.1 oil pan x Oil pump No.1 oil pan x Rear oil seal retainer Oil strainer x Main bearing cap Oil strainer x Oil pump No.2 oil pan x No. 1 oil pan Water pump x Cylinder block Water inlet housing x Cylinder block Knock sensor x Cylinder block No.2 idler pulley bracket x Cylinder block A/C compressor housing bracket x Cylinder block Generator bracket x Cylinder block Drive plate x Crankshaft Transaxle x Engine No.2 oil pan x Transaxle Drive plate x Torque convertor clutch Front exhaust pipe stay x No.1 oil pan RR engine mounting insulator x Cylinder block FR engine mounting insulator x Cylinder block FR engine mounting insulator x Front suspension member (TMC made) FR engine mounting insulator x Front suspension member (TM M made) Engine mounting absorber x Front suspension member Engine mounting absorber x Transaxle RR engine mounting insulator x Front suspension member LH engine mounting insulator x Transaxle PS pump x PS pump bracket PS pump x Hydraulic cooling fan pressure hose A/C compressor x Generator bracket A/C compressor x Cylinder block – ENGINE MECHANICAL EG2–196 1MZ–FE ENGINE – FE ENGINE – EMISSION CONTROL SYSTEMS EMISSION CONTROL SYSTEMS DESCRIPTION The emission control systems are installed to reduce the amount of HC, CO and NOx emitted from the engine, and to also prevent release of evaporated fuel from the gasoline tank and prevent atmospheric release of blow–by gas. The system consists of the PCV, EVAP, EGR and TWC. The function of each system is shown in the following table. System Positive crankcase ventilation Evaporative emission control Exhaust gas recirculation Three–way catalytic converter Sequential multiport fuel injection’ Abbreviation PCV EVAP EGR TWC SFI *For inspection and repair of the SFI system, refer to the SFI section. Purpose Reduces blow–by gas Reduces evaporative HC Reduces NOx Reduces C0, HC and NOx Regulates all engine conditions for reduction of exhaust emissions. EG2–197 1MZ–FE ENGINE COMPONENT LAYOUT – EMISSION CONTROL SYSTEMS EG2–198 1MZ–FE ENGINE SCHEMATIC DRAWING – EMISSION CONTROL SYSTEMS EG2–199 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS PREPARATION SST (SPECIAL SERVICE TOOL) 09843–18020 Diagnosis Check Wire RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set EQUIPMENT Tachometer Torque wrench Vacuum gauge SSM (SPECIAL SERVICE MATERIALS) 08833–00070 Adhesive 1311, THREE BOND 1311 or equivalent TVV EG2–200 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM DESCRIPTION To reduce HC emission, crankcase blow–by gas is routed through the PCV valve to the air intake chamber for combustion in the cylinders. OPERATION Engine not Running Normal Operation Idling or Deceleration Acceleration or High Load EG2–201 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS PCV VALVE INSPECTION 1. REMOVE PCV VALVE (a) Disconnect the PCV hose from the PCV valve. (b) Remove the PCV valve. 2. INSTALL CLEAN HOSE TO PCV VALVE 3. INSPECT PCV VALVE OPERATION (a) Blow air into the cylinder head side, and check that air passes through easily. CAUTION: Do not suck sir through the valve. Petroleum substances inside the valve are harmful. (b) Blow air into the intake manifold side, and check that air passes through with difficulty. If operation is not as specified, replace the PCV valve. 4. REMOVE CLEAN HOSE FROM PCV VALVE 5. REINSTALL PCV VALVE PCV HOSES AND CONNECTORS INSPECTION VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. EG2–202 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM DESCRIPTION To reduce HC emission, evaporated fuel from the fuel tank is routed through the charcoal canister to the intake manifold for combustion in the cylinders. OPERATION Engine Coolant Temp. Below 40
C (104
F) Above 59
C (138
F) TVV Throttle Valve Position Canister Check Valve Check Valve in Tank Cap Evaporated Fuel (HC) CLOSED OPEN HC from tank is absorbed into the canister. Positioned below port P CLOSED Positioned above port P OPEN HC from canister is led into air intake chamber. Nigh pressure in tank OPEN CLOSED CLOSED High vacuum in take CLOSED OPEN OPEN HC from tank is absorbed into the canister. Air is led into the fuel tank EG2–203 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS FUEL VAPOR LINES, FUEL TANK AND TANK CAP INSPECTION 1. VISUALLY INSPECT LINES AND CONNECTIONS Look for loose connections, sharp bends or damage. 2. VISUALLY INSPECT FUEL TANK Look for deformation, cracks or fuel leakage. 3. VISUALLY INSPECT FUEL TANK CAP Check if the cap and/or gasket are deformed or damaged. If necessary, repair or replace the cap. CHARCOAL CANISTER INSPECTION 1. REMOVE CHARCOAL CANISTER 2. VISUALLY INSPECT CHARCOAL CANISTER Look for cracks or damage. 3. CHECK FOR CLOGGED FILTER AND STUCK CHECK VALVE (a) Blow low pressure compressed air (4.71 kPa, 48 gf/cm2. 0.68 psi) into port A and check that air flows without resistance from the other ports. (b) Blow low pressure compressed air (4.71 kPa, 48 gf/cm2, 0.68 psi) into port B and check that air does not flow from the other ports. If a problem is found, replace the charcoal canister. EG2–204 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS 4. CLEAN FILTER IN CANISTER Clean the filter by blowing 294 kPa (3 kgf/cm2, 43 psi) of compressed air into port A while holding port B closed. NOTICE: • Do not attempt to wash the canister. • No activated carbon should come out. 5. REINSTALL CHARCOAL CANISTER TVV INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE TVV FROM INTAKE MANIFOLD 3. INSPECT TVV OPERATION (a) Cool the TVV to below 40
C (104
F) with cool water. (b) Check that air does not flow from the upper port to lower port. (c) Heat the TVV to above 59
C (138
F) with hot water. (d) Check that air flows from the upper port to lower port. If operation is not as specified, replace the TVV. 4. REINSTALL TVV Apply adhesive to 2 or 3 threads of the TVV, and install it. Adhesive: Part No. 08833–00070, THREE BOND 1324 or equivalent Torque: 30 N–m (305 kgf–cm, 22 ft–lbf) 5. REFILL WITH ENGINE COOLANT EG2–205 1MZ–FE ENGINE – FE ENGINE – EMISSION CONTROL SYSTEMS CHECK VALVE INSPECTION 1. REMOVE CHECK VALVE 2. INSPECT CHECK VALVE (a) Check that air flows from the yellow port to the black port. (b) Check that air does not flow from the black port to the yellow port. If operation is not as specified, replace check valve. 3. REINSTALL CHECK VALVE HINT: Reinstall the check valve with the black port facing the purge port side. EG2–206 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS EXHAUST GAS RECIRCULATION (EGR) SYSTEM DESCRIPTION To reduce NOx emission, part of the exhaust gases are recirculated through the EGR valve to the intake manifold to lower the maximum combustion temperature. OPERATION EG2–207 1MZ–FE ENGINE Engine Coolant Temp. VSV Below 55°C (131°F) ON OPENS passage to atmosphere Throttle Valve Position – EMISSION CONTROL SYSTEMS Pressure in the EGR Valve Pressure Chamber EG R Vacuum Modulator Exhaust Gas Not CLOSED recirculated Positioned below port E Above 60°C (140°F) EG R Valve CLOSED (1) LOW OFF Positioned between CLOSED passage port E and port R (2) to atmosphere HIGH Positioned above port R (3) HIGH *Pressure con– stantly alternating between low and high OPENS passage to atmosphere Not recirculated Not CLOSED recirculated CLOSES passage OPEN to atmosphere’ Recirculated CLOSES passage, OPEN to atmosphere Recirculated (increase) * Pressure increase → Modulator closes → EGR valve opens→ Pressure drops EGR valve closes← Modulator opens ** When the throttle valve is positioned above port R, the EGR vacuum modulator will close the atmosphere passage and open the EGR valve to increase the EGR gas, even if the exhaust pressure is insufficiently low. EGR SYSTEM INSPECTION 1. CHECK AND CLEAN FILTER IN EGR VACUUM MODULATOR (a) Remove the cap and filter. (b) Check the filter for contamination or damage. (c) Using compressed air, clean the filter. (d) Reinstall the filter and cap. HINT: Install the filter with the coarser surface facing out to the atmospheric side. 2. INSTALL VACUUM GAUGE Using a 3–way connector, connect a vacuum gauge to the hose between the EGR valve and EGR VSV. 3. INSPECT SEATING OF EGR VALVE Check that the engine starts and runs at idle. 4. CONNECT TERMINALS TE1 AND E1 Using SST, connect terminal TE1 and E1 of the data link connector 1. SST 09843–18020 EG2–208 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS 5. INSPECT VSV OPERATION WITH COLD ENGINE (a) The engine coolant temperature should be below 55
C (1131
F). (b) Check that the vacuum gauge indicates zero at 2,800 rpm. (c) Check that the EGR pipe is not hot. 6. INSPECT OPERATION OF VSV AND EGR VACUUM MODULATOR WITH HOT ENGINE (a) Warm up the engine to above 80
C (176° F). (b) Check that the vacuum gauge indicates low vacuum at 2,800 rpm. (c) Disconnect the vacuum hose from port R of the EGR vacuum modulator and connect port R directly to the intake manifold with another hose. (d) Check that the vacuum gauge indicates high vacuum at 3,500 rpm. HINT: As exhaust gas is increasingly recirculated, the engine will start to misfire. 7. DISCONNECT TERMINALS TE1 AND E1 Remove the SST from the data link connector 1. SST 09843–18020 EG2–209 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS 8. REMOVE VACUUM GAUGE Remove the vacuum gauge, and reconnect the vacuum hoses to their proper locations. 9. INSPECT EGR VALVE (a) Apply vacuum directly to the EGR valve with the engine idle. (b) Check that the engine runs rough or dies. (c) Reconnect the vacuum hoses to their proper loca– tions. IF NO PROBLEM IS FOUND DURING THIS INSPECTION, SYSTEM IS NORMAL; OTHERWISE INSPECT EACH PART VSV INSPECTION 1. REMOVE VSV 2. INSPECT VSV A. Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance: 33 – 39  at 20
C (68
F) If there is no continuity, replace the VSV. B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. !f there is continuity, replace the VSV. EG2–210 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS C. Inspect VSV operation (a) Check that the air flows from ports E to G. (b) Apply battery voltage across the terminals. (c) Check that the air flows from port E to the gas filter. If operation is not as specified, replace the VSV. 3. REINSTALL VSV EGR VACUUM MODULATOR INSPECTION 1. DISCONNECT VACUUM HOSES FROM EGR VACUUM MODULATOR Disconnect the following vacuum hoses: (1) Vacuum hose from P port (2) Vacuum hose from Q port (3) Vacuum hose from R port 2. INSPECT EGR VACUUM MODULATOR OPERATION (a) Block ports P and R with your finger. (b) Blow air into port Q, and check that the air passes through to the air filter side freely. (c) Start the engine, and maintain speed at 3,500 rpm. (d) Repeat the above test. Check that there is a strong resistance to air flow. EG2–211 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS 3. RECONNECT VACUUM HOSES TO EGR VACUUM MODULATOR Connect the following vacuum hoses: (1) Vacuum hose to P port (2) Vacuum hose to Q port (3) Vacuum hose to R port EGR VALVE INSPECTION 1. REMOVE EGR PIPE Remove the 4 nuts, EGR pipe and 2 gaskets. 2. DISCONNECT EGR GAS TEMPERATURE SENSOR CONNECTOR AND CLAMP 3. REMOVE EGR VALVE AND VACUUM MODULATOR ASSEMBLY (a) Disconnect the following hoses: . (1) Vacuum hose from P port of EGR vacuum modu– lator (2) Vacuum hose from Q port of EGR vacuum modu– lator (3) Vacuum hose from R port of EGR vacuum modu– lator (4) Vacuum hose from EGR valve (b) Remove the 3 nuts, EGR valve and vacuum modulator assembly and gasket. EG2–212 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS 4. SEPARATE EGR VALVE AND VACUUM MODULATOR (a) Remove the nut and disconnect the EGR vacuum modulator. (b) Disconnect the pressure hose from the EGR valve and remove the EGR vacuum modulator. 5. REMOVE EGR GAS TEMPERATURE SENSOR 6. INSPECT EGR VALVE Check for sticking and heavy carbon deposits. If a problem is found, replace the EGR valve. EG2–213 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS 7. REINSTALL EGR GAS TEMPERATURE SENSOR Torque: 20 N–m (200 kgf–cm, 14 ft–lbf) 8. REASSEMBLE EGR VALVE AND VACUUM MODULATOR (a) Connect the pressure hose to the EGR valve. (b) Install the EGR vacuum modulator with the nut. Torque: 12 N–m (120 kgf–cm, 9 ft–lbf) 9. REINSTALL EGR VALVE AND VACUUM MODULATOR ASSEMBLY (a) Install the EGR valve and vacuum modulator assembly to the air intake chamber. EG2–214 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS (b) Install and torque the 3 nuts. Torque: 12 N–m (120 kgf–cm, 9 ft–lbf) (c) Connect the following vacuum hoses: (1) Vacuum hose to P port of EGR vacuum modula– tor (2) Vacuum hose to a port of EGR vacuum modula– tor (3) Vacuum hose to R port of EGR vacuum modula– tor (4) Vacuum to EGR valve 10. RECONNECT EGR GAS TEMPERATURE SENSOR CONNECTOR AND CLAMP 11. REINSTALL EGR PIPE Install 2 new gaskets and the EGR pipe with the 4 nuts. Torque: 12 N–m (120 kgf–cm, 9 ft–lbf) EG2–215 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS THREE–WAY CATALYTIC CONVERTER (TWC) SYSTEM DESCRIPTION To reduce HC. CO and NOx emissions, they are oxidized, reduced and converted to nitrogen (N2), carbon dioxide (C02) and water (H20) by the three–way catalytic converter. OPERATION Exhaust port TWC HC, CO, AND NOx OXIDATION AND REDUCTION Exhaust Gas CO2 H2O N2 EXHAUST PIPE ASSEMBLY INSPECTION 1. CHECK CONNECTIONS FOR LOOSENESS OR DAMAGE 2. CHECK CLAMPS FOR WEAKNESS. CRACKS OR DAMAGE THREE–WAY CATALYTIC CONVERTER INSPECTION CHECK FOR DENTS OR DAMAGE If any part of the protector is damaged or dented to the extent that it contacts the three–way catalytic converter, repair or replace it. EG2–216 1MZ–FE ENGINE – EMISSION CONTROL SYSTEMS HEAT INSULATOR INSPECTION 1. CHECK HEAT INSULATOR FOR DAMAGE 2. CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSULATOR THREE–WAY CATALYTIC CONVERTER REPLACEMENT 1. REMOVE CONVERTER (a) Jack up the vehicle. (b) Check that the converter is cool. (c) Remove the 4 bolts and nuts holding the pipes to the converter. (d) Remove the converter and 2 gaskets. 2. REINSTALL CONVERTER (a) Place 2 new gaskets on the front and rear pipes. (b) Install the converter with the bolts and nuts. Torque the bolts and nuts. Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) SERVICE SPECIFICATIONS SERVICE DATA VSV for EGR Resistance TORQUE SPECIFICATIONS Part tightened TVV x Cylinder heed EGR gas temperature x EGR valve EGR vacuum modulator x EGR valve EGR valve x Air intake chamber EGR pipe x Air intake chamber EGR pipe x EGR cooler Three –way catalytic converter x Front exhaust pipe Three–way catalytic converter x Center exhaust pipe et 20
C (68
F) 33 –39
EG2–217 1MZ–FE ENGINE – SFI SYSTEM SFI SYSTEM DESCRIPTION EG2–218 1MZ–FE ENGINE – SFI SYSTEM The SFI (Sequential Multiport Fuel Injection) system is composed of 3 basic sub–systems: Fuel, Air Induction and Electronic Control Systems. FUEL SYSTEM Fuel is supplied under constant pressure to the SFI injectors by an electric fuel pump. The injectors inject a metered quantity of fuel into the intake manifold in accordance with signals from the ECM (Engine Control Module). AIR INDUCTION SYSTEM The air induction system provides sufficient air for engine operation. ELECTRONIC CONTROL SYSTEM The 1 MZ–FE engine is equipped with a TOYOTA Computer Controlled System (TCCS) which centrally controls the SFI, ESA, IAC, diagnosis systems etc. by means of ECM–formerly SFI computer employing a microcomputer. The ECM controls the following functions: 1. Sequential Multiport Fuel Injection (SFI) The ECM receives signals from various sensors indicating changing engine operation conditions such as: Intake air volume Intake air temperature (IAT) Engine coolant temperature (ECT) Engine speed (RPM) Acceleration/deceleration Exhaust oxygen content etc. The signals are utilized by the ECM to determine the injection duration necessary for an optimum air–fuel ratio. 2. Electronic Spark Advance (ESA) The ECM is programmed with data for optimum ignition timing under all operating conditions. Using data provided by sensors which monitor various engine functions (RPM, ECT, etc.), the ECM triggers the spark at precisely the right instant. 3. Idle Air Control (IAC) The ECM is programmed with target idling speed values to respond to different engine conditions (ECT, A/C (air conditioning) ON/OFF, etc.). Sensors transmit signals to the ECM which control the flow of air through the throttle valve bypass and adjust idle speed to the target value. 4. Diagnosis The ECM detects any malfunctions and abnormalities in the sensor network and lights a malfunction indicator lamp (MIL) on the combination meter. At the same time, the trouble is identified and a diagnostic trouble code is recorded by the ECM. The diagnostic trouble codes are referred in the Engine Troubleshooting. (See page EG2–404) 5. Fail–Safe Function In the event of the sensor malfunctioning, a back–up circuit will take over to provide minimal driveability, and the malfunction indicator lamp will illuminate. EG2–219 1MZ–FE ENGINE SYSTEM CIRCUIT – SFI SYSTEM EG2–220 1MZ–FE ENGINE – SFI SYSTEM OPERATION FUEL SYSTEM Fuel is pumped up by the fuel pump, which flows through the fuel filter under pressure through the fuel pipe to the delivery pipe where it is distributed to each injector. The fuel pressure regulator adjusts the pressure of the fuel from the fuel line (high pressure side) to a pressure 284 kPa (2.9 kgf/cm2, 41 psi) higher than the pressure inside the intake manifold, and excess fuel is returned to the fuel tank through the return tube. When the engine is hot, the fuel pressure is increased to control percolation in the fuel system and improve restartability and idling stability. The pulsation damper absorbs the slight fluctuations in fuel pressure caused by the injector. Fuel is injected into the intake manifold according to signals from the ECM. EG2–221 1MZ–FE ENGINE – SFI SYSTEM AIR INDUCTION SYSTEM Air filtered through the air cleaner passes through the MAF meter and the amount flowing to the air intake chamber is determined by the throttle valve opening in the throttle body and the engine speed. The MAF meter measures the intake flow to the engine by measuring the air’s cooling effect on the thermistor which is heated by the heater. Located in the throttle body is the throttle valve, which regulates the volume of air intake to the engine. Air intake controlled by the throttle valve opening is distributed from the intake chamber to the manifold of each cylinder and is drawn into the combustion chamber. At low air temperatures the IAC valve opens and the air flows through the IAC valve, as well as the throttle body, into the air intake chamber. During engine warm up, fast idle is accomplished by air flowing into the intake chamber via the IAC valve, even when the throttle valve is completely closed. In this way the IAC valve controls the idle speed to suit the operating conditions. The air intake chamber prevents pulsation of the intake air, reduces the influence of the MAF meter and increases the air intake volume. It also prevents intake air interference in each cylinder. There is also the intake air control valve attached to the air intake chamber. Part of the ACIS, the ECM provides signals to the VSV to open or close. This valve opens or closes the vacuum source to the actuator, which in turn opens or closes the intake air control valve. The intake air control valve is designed to modify the effective manifold length in 2 stages for increased power in all driving ranges. EG2–222 1MZ–FE ENGINE – SFI SYSTEM ELECTRONIC CONTROL SYSTEM The control system consists of sensors which detect various engine conditions, and an ECM which determines the injection volume (timing) based on the signals from the sensors. The various sensors detect the intake air volume, engine speed, oxygen density in the exhaust gas, engine coolant temperature and intake air temperature etc. and convert the information into an electrical signal which is sent to the ECM; Based on these signals, the ECM calculates the optimum ignition timing for the current conditions and operates the injectors. The ECM not only controls the fuel injection timing, but also the self diagnostic function which records the occurrence of a malfunction, fuel volume and timing injection control, idle speed control, fuel pressure control, knock sensor control and EGR control. EG2–223 1MZ–FE ENGINE – SFI SYSTEM PREPARATION SST (SPECIAL SERVICE TOOLS) 09268–41045 Injection Measuring Tool Set (09268–41080) No.6 union (09268–41090) No.7 Union (90405–09015) No.1 Union 09268–45012 EFI Fuel Pressure Gauge 09631 –22020 Power Steering Hose Nut 14 x 17 mm Wrench Set Fuel line flare nut 09842–30070 Wiring ”F” EFI Inspection 09843–18020 Diagnosis Check Wire RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set 09200–00010 Engine Adjust Kit 09258–00030 Hose Plug Set Plug for the vacuum hose, fuel hose etc. EG2–224 1MZ–FE ENGINE – SFI SYSTEM EQUIPMENT Graduated cylinder Injector Carburetor cleaner Throttle body Sound scope Injector Tachometer Torque wrench Vacuum gauge Soft brush Throttle body SSM (SPECIAL SERVICE MATERIALS) 08826–00080 Seal packing or equivalent Intake air control valve COOLANT Item Engine coolant Capacity 8.7 liters (9.2 US qts, 7.7 Imp. qts) Classification Ethylene–glycol base EG2–225 1MZ–FE ENGINE – SFI SYSTEM PRECAUTION 1. Before working on the fuel system, disconnect the negative (–) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the computer will be erased when the battery terminal is removed. Therefore, if necessary, read the diagnosis before removing the battery terminal. CAUTION: Work must be started after 90 seconds from the time the Ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. Do not smoke or work near an open flame when working on the fuel system. 3. Keep gasoline away from rubber or leather parts. MAINTENANCE PRECAUTIONS 1. CHECK CORRECT ENGINE TUNE–UP (See page EG2–8) 2. PRECAUTIONS WHEN CONNECTING GAUGE (a) Use the battery as the power source for the timing light, tachometer, etc. (b) Connect the tester probe of a tachometer to the termi– nal IG(–) of the DLC1. 3. IN EVENT OF ENGINE MISFIRE, FOLLOWING PRE– CAUTIONS SHOULD BE TAKEN (a) Check proper connection of battery terminals, etc. (b) After repair work, check that the ignition coil termi– nals and all other ignition system lines are reconne– cted securely. (c) When cleaning the engine compartment, be especially careful to protect the electrical system from water. 4. PRECAUTIONS WHEN HANDLING OXYGEN SENSOR (a) Do not allow oxygen sensor to drop or hit against an object. (b) Do not allow the sensor to come into contact with water. EG2–226 1MZ–FE ENGINE – SFI SYSTEM IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYSTEM (HAM, CB, ETC.) If the vehicle is equipped with a mobile communica– tion system, refer to the precaution in the IN section. AIR INDUCTION SYSTEM 1. Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run out of tune. 2. Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run out of tune. ELECTRONIC CONTROL SYSTEM 1. Before removing SFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch to LOCK or disconnecting the negative (–) terminal cable from the battery. HINT: Always check the diagnostic trouble code before disconnecting the negative (–) terminal cable from the battery. 2. When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative (–) cables. 3. Do not permit parts to receive a severe impact during removal or installation. Handle all SFI parts carefully, especially the ECM. 4. Do not be careless during troubleshooting as there are numerous transistor circuits and even slight terminal contact can cause further troubles. 5. Do not open the ECM cover. 6. When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting or the SFI parts and wiring connectors. 7. Parts should be replaced as an assembly. EG2–227 1MZ–FE ENGINE – SFI SYSTEM 8. Care is required when pulling out and inserting wiring connectors. (a) Release the lock and pull out the connector, pulling on the connectors. (b) Fully insert the connector and check that it is locked. 9. Use SST for inspection or test of the injector or its wiring connector. SST 09842–30070 FUEL SYSTEM 1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedures: (a) Put a container under the connection. (b) Slowly loosen the connection. (c) Disconnect the connection. (d) Plug the connection with a rubber plug. 2. When connecting the flare nut or union bolt on the high pressure pipe union, observe the following proce– dures: Union Bolt Type: (a) Always use 2 new gaskets. (b) Tighten the union bolt by hand. (c) Tighten the union bolt to the specified torque. Torque: 30 N–m (310 kgf–cm, 22 ft–lbf) EG2–228 1MZ–FE ENGINE – SFI SYSTEM Flare Nut Type: (a) Apply a light coat of engine oil to the flare nut, and tighten the flare nut by hand. M Using SST, tighten the flare nut to specified torque. SST 09631– 22020 NOTICE: Do not rotate the fuel pipe, when tightening the flare nut. Torque: 28 N–m (285 kgf–cm, 21 ft–lbf) for fuel pump side 30 N–m (310 kgf–cm, 22 ft–lbf) for others HINT: Use a torque wrench with a fulcrum length of 30 cm (111.81 in.). 3. Observe the following precautions when removing and installing the injectors. (a) Never reuse the O–ring. (b) When placing a new 0 –ring on the injector, take care not to damage it in any way. (c) Coat a new 0 –ring with spindle oil or gasoline before installing– never use engine, gear or brake oil. 4. Install the injector to the delivery pipe and intake manifold as shown in the illustration. 5. Check that there are no fuel leaks after performing any maintenance on the fuel system. (a) Using SST, connect terminals +B and FP of the DLC 1. SST 09843–18020 EG2–229 1MZ–FE ENGINE – SFI SYSTEM (b) With engine stopped, turn the ignition switch ON. (c) Pinch the fuel return hose. The pressure in the high pressure line will rise to approx. 392 kPa (4 kgf/cm2 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTICE: Always pinch the hose. Avoid bending as it may cause the hose to crack. (d) Turn the ignition switch to LOCK. (e) Remove the SST from the DLC1. SST 09843–18020 EG2–230 1MZ–FE ENGINE – SFI SYSTEM FUEL PUMP ON–VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION (a) Using SST, connect terminals +B and FP of the DLC 1. SST 09843–18020 (b) Turn the ignition switch ON. NOTICE: Do not start the engine. (c) Check that there is pressure in the fuel inlet hose from the fuel filter. HINT: If there is fuel pressure, you will hear the sound of fuel flowing. If there is no pressure, check the following parts: • Fusible link • Fuses (AM2 30A, IGN 7.5A) • EFI main relay • Fuel pump • ECM • Wiring connections (d) Turn the ignition switch to LOCK. EG2–231 1MZ–FE ENGINE – SFI SYSTEM (e) Remove the SST from the DLC1. SST 09843–18020 2. CHECK FUEL PRESSURE (a) Check the battery voltage is above 12 V. (b) Disconnect the negative (–) terminal cable from the battery. CAUTION: Work must be started after 90 seconds from the time the ignition switch Is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. (c) Remove the union bolt and 2 gaskets, and disconnect the fuel inlet hose from the fuel filter outlet. CAUTION: • Put a shop towel under the fuel filter. • Slowly loosen the union bolt. (d) Install the fuel inlet hose and SST (pressure gauge) to the fuel filter outlet with 3 new gaskets and the union bolt. SST 09268–45012 Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) (e) Wipe off any splattered gasoline. EG2–232 1MZ–FE ENGINE – SFI SYSTEM (f) Using SST, connect terminals +B and FP of the DLC 1. (g) Reconnect the negative (–) terminal cable to the battery. (h) Turn the ignition switch ON. (i) Measure the fuel pressure. Fuel pressure: 266 – 304 kPa (2.7 – 3.1 kgf/cm2, 38 – 44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the following parts: • Fuel hoses and connections • Fuel pump • Fuel filter • Fuel pressure regulator (j) Remove the SST from the DLC1. SST 09843–18020 (k) Start the engine. (l) Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. EG2–233 1MZ–FE ENGINE – SFI SYSTEM (m) Measure the fuel pressure at idle. Fuel pressure: 265 – 304 kPa (2.7 – 3.1 kgf/cm2, 39 – 44 psi) (n) Reconnect the vacuum sensing hose to the fuel pres– sure regulator. (o) Measure the fuel pressure at idle. Fuel pressure: 226 – 265 kPa (2.3 – 2.7 kgf/cm2, 33 – 38 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. (p) Stop the engine. (q) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/cm2, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injectors. (r) After checking fuel pressure, disconnect the negative (–) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268–45012 EG2–234 1MZ–FE ENGINE – Sf=I SYSTEM (s) Connect the fuel inlet hose with 2 new gaskets and the union bolt. Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) (t) Reconnect the negative (–) terminal cable to the battery. (u) Check for fuel leakage. (See page EG2–228) FUEL PUMP INSPECTION 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE REAR SEAT CUSHION 3. INSPECT FUEL PUMP A. Inspect fuel pump resistance Using an ohmmeter, measure the resistance between terminals 4 and 5. Resistance: 0.2–3.0
at 20
C (88
F) If the resistance is not as specified, replace the fuel pump. B. Inspect fuel pump operation Connect the positive (+) lead from the battery to terminal 4 of the connector, and the negative (–) lead to terminal 5. Check that the fuel pump operates. NOTICE: • These tests must be performed quickly (within 10 seconds) to prevent the coil burning out. • Keep the fuel pump as far away from the battery as possible. • Always perform switching at the battery side. If operation is not as specified, replace the fuel pump or lead wire. 4. REINSTALL REAR SEAT CUSHION 5. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG2–235 1MZ–FE ENGINE – SFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION FUEL PUMP REMOVAL (See Components for Removal and Installation) CAUTION: Do not smoke or work near an open flame when working on the fuel pump. 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE REAR SEAT CUSHION EG2–236 1MZ–FE ENGINE – SFI SYSTEM 3. REMOVE FLOOR SERVICE HOLE COVER (a) Disconnect the fuel pump connector. (b) Remove the 5 screws and service hole cover. 4. REMOVE FUEL PUMP LEAD WIRE NOTICE: Do not lift the fuel pump up with the wire harness picking. 5. DISCONNECT FUEL PIPE AND HOSE FROM FUEL PUMP BRACKET CAUTION: Remove the fuel filter cap to prevent the fuel from flowing out. (a) Using SST, disconnect the outlet pipe from the pump bracket. SST 09631– 22020 (b) Disconnect the return hose from the pump bracket. 6. REMOVE FUEL PUMP BRACKET ASSEMBLY FROM FUEL TANK (a) Remove the 8 bolts. (b) Pull out the pump bracket assembly. (c) Remove the gasket from the pump bracket. EG2–237 1MZ–FE ENGINE – SFI SYSTEM COMPONENTS FOR DISASSEMBLY AND ASSEMBLY FUEL PUMP DISASSEMBLY (See Components for Disassembly and Assembly) 1. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET (a) Remove the fuel pump lead wire. (b) Pull off the lower side of the fuel pump from the pump bracket. (c) Disconnect the fuel hose from the fuel pump, and remove the fuel pump. (d) Remove the rubber cushion from the fuel pump. 2. REMOVE FUEL SENDER GAUGE FROM FUEL PUMP BRACKET (a) Disconnect the fuel sender gauge connector. (b) Remove the 2 screws and sender gauge. EG2–238 1MZ–FE ENGINE – SFI SYSTEM 3. REMOVE FUEL PUMP FILTER FROM FUEL PUMP (a) Using a small screwdriver, remove the clip. (b) Pull out the pump filter. 4. REMOVE CONNECTOR Remove the 2 screws, connector support, connector and gasket. FUEL PUMP ASSEMBLY (See Components for Disassembly and Assembly) 1. INSTALL CONNECTOR Install new gasket, the connector and connector sup– port with the 2 screws. 2. INSTALL FUEL PUMP FILTER TO FUEL PUMP Install the pump filter with a new clip. 3. INSTALL FUEL SENDER GAUGE TO FUEL PUMP BRACKET (a) Install the sender gauge with the 2 screws. (b) Connect the fuel sender gauge connector. 4. INSTALL FUEL PUMP TO FUEL PUMP BRACKET (a) Install the rubber cushion to the fuel pump. (b) Connect the fuel hose to the outlet port of the fuel pump. (c) Install the fuel pump by pushing the lower side of the fuel pump. (d) Install the fuel pump connector. EG2–239 1MZ–FE ENGINE – SFI SYSTEM FUEL PUMP INSTALLATION (See Components for Removal and Installation) 1. INSTALL FUEL PUMP BRACKET ASSEMBLY TO FUEL TANK (a) Install a new gasket to the pump bracket. (b) Insert the pump bracket assembly into the fuel tank. NOTICE: • Do not damage the fuel pump filter. • Be careful that the arm of the sender gauge should not bent. (c) Install the pump bracket with the 8 screws. Torque: 4 N–m (40 kgf–cm, 35 in.–lbf) 2. CONNECT FUEL PIPE AND HOSE TO FUEL PUMP BRACKET (a) Using SST, connect the outlet pipe to the pump bracket. SST 09631– 22020 Torque: 28 N–m (285 kgf–cm, 21 ft–lbf) for use with SST (b) Connect the return hoses to the pump bracket. 3. CONNECT FUEL PUMP LEAD WIRE 4. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 6. CHECK FOR FUEL LEAKAGE (See page EG2–228) Connect the fuel pump (with fuel sender gauge) con– nector. 6. INSTALL FLOOR SERVICE HOLE COVER Install the service hole cover with the 5 screws. 7. INSTALL REAR SEAT CUSHION EG2–240 1MZ–FE ENGINE – SFI SYSTEM FUEL PRESSURE REGULATOR ON–VEHICLE INSPECTION CHECK FUEL PRESSURE (See page EG2–231) COMPONENTS FOR REMOVAL AND INSTALLATION EG2–241 1MZ–FE ENGINE – SFI SYSTEM FUEL PRESSURE REGULATOR REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR 3. DISCONNECT FUEL RETURN HOSE FROM FUEL PRESSURE REGULATOR CAUTION: Put a shop rag under the pressure regulator. 4. REMOVE FUEL PRESSURE REGULATOR (a) Remove the 2 bolts, and pull out the pressure regula– tor. (b) Remove the 0–ring from the pressure regulator. FUEL PRESSURE REGULATOR INSTALLATION (See Components for Removal and Installation) 1. INSTALL FUEL PRESSURE REGULATOR (a) Apply a light coat of gasoline to a new 0–ring, and install it to the pressure regulator. EG2–242 1MZ–FE ENGINE – SFI SYSTEM (b) Attach the pressure regulator to the delivery pipe. (c) Check that the pressure regulator rotates smoothly. NOTICE: If it does not rotate smoothly, the O–ring may be pinched, so remove the pressure regulator and repeat steps (a) to (e) above. (d) Install the pressure regulator with the 2 bolts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) 2. CONNECT FUEL RETURN HOSE TO FUEL PRES– SURE REGULATOR NOTICE: Be sure insert the hose up to the stopper and clip It. 3. CONNECT VACUUM SENSING HOSE TO FUEL PRESSURE REGULATOR 4. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 5. CHECK FOR FUEL LEAKS (See page EC–228) EG2–243 1MZ–FE ENGINE – SFI SYSTEM INJECTOR ON–VEHICLE INSPECTION 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE V–BANK COVER Using a 5 mm hexagon wrench, remove the 2 cap nuts and V–bank cover. EG2–244 1MZ–FE ENGINE – SFI SYSTEM 3. INSPECT INJECTOR OPERATION Check operation sound from each injector. (a) With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine speed. (b) If you have no sound scope, you can check the injec– tor operating vibration with your finger. If no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the ECM. 4. INSPECT INJECTOR RESISTANCE (a) Disconnect the injector connector. (b) Using an ohmmeter, measure the resistance between the terminals. Resistance: Approx. 13.8
at 20° C (68° F) If the resistance is not as specified, replace the injec– tor. (c) Reconnect the injector connector. 5. REINSTALL V–BANK COVER Using a 5 mm hexagon wrench, install the V–bank cover with the 2 cap nuts. HINT: For fixing the V–bank cover, push on the cover until sense of ”click” is felt. 6. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG2–245 1MZ–FE ENGINE – SFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION EG2–246 1MZ–FE ENGINE – SFI SYSTEM INJECTORS REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the Ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. DRAIN ENGINE COOLANT 3. DISCONNECT ACCELERATOR CABLE 4. DISCONNECT THROTTLE CABLE 6. REMOVE AIR CLEANER HOSE (a) Disconnect the PCV hose. (b) Loosen the 2 hose clamps, and remove the air cleaner hose. 6. REMOVE V–SANK COVER Using a 5 mm hexagon wrench, remove the 2 cap nuts and v–bank cover. 7. REMOVE EMISSION CONTROL VALVE SET (a) Disconnect the following vacuum hoses: (1) Vacuum hose from VSV for ACIS (2) Vacuum hose from EGR vacuum modulator (3) Vacuum hose from EGR valve (4) Vacuum hose (from cylinder head rear plate) (5) Vacuum hose from air intake chamber (6) Vacuum hose from fuel pressure regulator EG2–247 1MZ–FE ENGINE – SFI SYSTEM (b) Disconnect the following connectors: (1) VSV connector for ACIS (2) VSV connector for EGR (3) VSV connector for fuel pressure control (c) Remove the 2 nuts and emission control valve set. 8. REMOVE No.2 EGR PIPE Remove the 4 nuts, EGR pipe and 2 gaskets. 9. DISCONNECT HYDRAULIC MOTOR PRESSURE PIPE Remove the 2 bolts, and disconnect the pressure pipe from the water inlet and air intake chamber. 10. REMOVE AIR INTAKE CHAMBER ASSEMBLY (a) Disconnect the 2 PS air hoses. (b) Remove the bolt holding the air intake chamber stay to the air intake chamber. EG2–248 1MZ–FE ENGINE – SFI SYSTEM (c) Disconnect the following connectors: (1) A/C idle–up valve connector (2) EGR gas temperature sensor connector (3) Throttle position sensor connector (4) IAC valve connector (d) Disconnect the following vacuum hoses: (1) Vacuum hose from charcoal canister (2) Vacuum hose from air intake chamber (3) 2 vacuum hoses from throttle body (e) Disconnect the following hoses: (1) 2 water bypass hoses from throttle body (2) Air assist hose from throttle body (f) Disconnect the following hoses: (1) Brake booster vacuum hose (2) PCV hose (3) Actuator vacuum hose (g) Disconnect the DLC1. (h) Remove the nut and disconnect the 2 ground straps. EG2–249 1MZ–FE ENGINE – SFI SYSTEM (i) Remove the nut and disconnect the PS pressure tube. (j) Remove the bolt holding the No.1 engine hanger to the air intake chamber. (k) Remove the bolt, and disconnect the ground strap. Using a 8 mm hexagon wrench, remove the 2 bolts, 2 nuts, air intake chamber assembly and gasket. 11. DISCONNECT INJECTOR CONNECTORS 12. REMOVE AIR ASSIST HOSES AND PIPE (a) Disconnect the air assit pipe from the bracket on the No.1 fuel pipe. (b) Remove the air assist hoses from the intake manifold. 13. DISCONNECT FUEL INLET AND RETURN HOSES (a) Disconnect the fuel return hose from the No.1 fuel pipe. (b) Disconnect the fuel inlet hose from the fuel filter. CAUTION: Catch leaking fuel in a container. EG2–250 1MZ–FE ENGINE – SFI SYSTEM 14. REMOVE DELIVERY PIPES AND INJECTORS NOTICE: Be careful not to drop the injectors when rem– oving the delivery pipes. (a) Loosen the 2 union bolts holding the No.2 fuel pipe to the delivery pipes. (b) Disconnect the fuel return hose from the fuel pressure regulator. (c) Remove the union bolt for the RH delivery pipe, 2 gaskets, 2 bolts, LH delivery pipe together with the 3 injectors and No.2 fuel pipe. (d) Remove the union bolt for the LH delivery pipe and 2 gaskets from the No.2 fuel pipe. (e) Remove the 3 bolts, RH delivery pipe together with the 3 injectors and No.1 fuel pipe. (f) Remove the 4 spacers from the intake manifold. (g) Pull out the 6 injectors from the delivery pipes. (h) Remove the 2 0 – rings and 2 grommets from each injector. INJECTORS INSPECTION 1. INSPECT INJECTOR INJECTION CAUTION: Keep injector clear of sparks during the test. EG2–251 1MZ–FE ENGINE – SFI SYSTEM (a) Disconnect the fuel hose from the fuel filter outlet. (b) Connect SST (union an hose) to the fuel filter outlet with 2 new gaskets and the union bolt. SST 09268–41045 (90405–09015) HINT: Use the vehicle’s fuel filter. (c) Remove the fuel pressure regulator. (d) Connect the fuel return hose, SST (hose) and SST (union) to the fuel pressure regulator. SST 09268–41045 (09268–41090) (e) Install a new O–ring to the injector. (f) Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268–41045 (g) Put the injector into the graduated cylinder. HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. (h) Using SST, connect terminals +B and FP of the DLC1. SST 00843–18020 (i) Reconnect the negative (–) terminal cable to the battery. (j) Turn the ignition switch ON. NOTICE: Do not start the engine. EG2–252 1MZ–FE ENGINE – FE ENGINE – SFI SYSTEM (k) Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector 2 or 3 times. SST 09842–30070 Volume: 54 – 64 cm3 (3.3 – 3.9 cu in.) per 15 sec. Difference between each injector: 5 cm3 (0.3 cu in.) or less If the ignition volume is not as specified, replace the injector. 2. INSPECT LEAKAGE (a) In the condition above, disconnect the test probes of SST (wire) from the battery and check the fuel leakage from the injector. SST 09842–30070 Fuel drop: 1 drop or less per minute (b) Disconnect the negative (–) terminal cable to the battery. (c) Remove SST. SST 09268–41045 and 09843–18020 (d) Reinstall the fuel pressure regulator to the delivery pipe. (See step 1 on pages EG2–241 and 242) Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) INJECTORS INSTALLATION (See Components for Removal and Installation) 1. INSTALL INJECTORS AND DELIVERY PIPES (a) Install 2 new grommets to each injector. (b) Apply a light coat of spindle oil or gasoline to 2 new 0 –rings and install them to each injector. (c) While turning the injector clockwise and counter– clockwise, push it to the delivery pipes. Install the 6 injectors. (d) Position the injector connector outward. EG2–253 1MZ–FE ENGINE – FE ENGINE – SFI SYSTEM (e) Place the 4 spacers in position on the intake manifold. (f) Place the RH delivery pipe and No.1 fuel pipe together with the 3 injectors in position on the intake manifold. (g) Temporarily install the 2 bolts holding the RH delivery pipe to the intake manifold. (h) Temporarily install the bolt holding the No.1 fuel pipe to the intake manifold. (i) Place the LH delivery pipe and No.2 fuel pipe together with the 3 injectors in position on the intake manifold. (j) Connect the fuel return hose to the fuel pressure regulator. (k) Temporarily install the 2 bolts holding the LH delivery pipe to the intake manifold. (l) Temporarily install the No.2 fuel pipe to the LH deliv– ery pipe with the union bolt and 2 new gaskets. (m) Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the probable cause is incorrect installation of 0–rings. Replace the O – rings. (n) Position the injector connector outward. (o) Tighten the 4 bolts holding the delivery pipes to the intake manifold. Torque: 10 N–m (100 kgf–cm, 7 ft–lbf) (p) Tighten the bolt holding the No.1 fuel pipe to the intake manifold. Torque: 19.5 N–m (200 kgf–cm, 14 ft–lbf) (q) Tighten the 2 union bolts holding the No.2 fuel pipe to the delivery pipes. Torque: 32.5 N–m (330 kgf–cm, 24 ft–lbf) EG2–254 1MZ–FE ENGINE – SFI SYSTEM 2. CONNECT FUEL INLET AND RETURN HOSES (a) Connect the fuel inlet hose to the fuel filter with the 2 new gaskets and union bolt. Torque: 30 N–m (300 kgf–cm, 22 ft–lbf) (b) Connect the fuel return hose to the No.1 fuel pipe. HINT: Pass the fuel return hose under the heater hoses. 3. INSTALL AIR ASSIST HOSES AND PIPE (a) Connect the air assist hoses to the intake manifold. (b) Install the air assist pipe to the bracket on the No.1 fuel pipe. 4. CONNECT INJECTOR CONNECTORS 5. INSTALL AIR INTAKE CHAMBER ASSEMBLY (a) Using a 8 mm hexagon wrench, install a new gasket and the air intake chamber assembly with the 2 bolts and 2 nuts. Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) (b) Connect the ground strap with the bolt. (c) Install the bolt holding the No.1 engine hanger to the air intake chamber. Torque: 39 N–m (400 kgf–cm, 29 ft–lbf) (d) Connect the PS pressure tube with the nut. EG2–255 1MZ–FE ENGINE – SFI SYSTEM (e) Connect the following hoses: (1) Brake booster vacuum hose (2) PCV hose (3) Actuator vacuum hose (f) Connect the DLC1. (g) Connect the 2 ground straps with the nut. Torque: 14.5 N–m (145 kgf–cm. 10 ft–lbf) (h) Connect the following hoses: (1) 2 water bypass hoses to throttle body (2) Air assist hose to throttle body (i) Connect the following vacuum hoses: (1) Vacuum hose to air intake chamber (2) 2 vacuum hoses to throttle body (3) Vacuum hose to charcoal canister (j) Connect the following connectors: (1) A/C idle–up valve connector (2) EGR gas temperature sensor connector (3) Throttle position sensor connector (4) IAC valve connector EG2–256 1MZ–FE ENGINE – FE ENGINE – SFI SYSTEM (k) Install the bolt holding the air intake chamber stay to the air intake chamber. Torque: 19.5 N–m (200 kgf–cm. 14 ft–lbf) (1) Connect the 2 PS air hoses. 6. CONNECT HYDRAULIC MOTOR PRESSURE PIPE Connect the pressure pipe to the air intake chamber and water inlet with the 2 bolts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) 7. INSTALL NO.2 EGR PIPE Install 2 new gaskets and the EGR pipe with the 4 nuts. Torque: 12 N–m (120 kgf–cm, 9 ft–lbf) 8. INSTALL EMISSION CONTROL VALVE SET (a) Install the emission control valve set with 2 bolts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) (b) Connect the following connectors: (1) VSV connector for ACIS (2) VSV connector for EGR (3) VSV connector for fuel pressure control EG2–257 1MZ–FE ENGINE – SFI SYSTEM (c) Connect the following vacuum hoses: (1) Vacuum hose to VSV for ACIS (2) Vacuum hose to EGR vacuum modulator (3) Vacuum hose to EGR valve (4) Vacuum hose (from cylinder head rear plate) (5) Vacuum hose from air intake chamber (6) Vacuum hose to fuel pressure regulator 9. INSTALL V–BANK COVER Using a 5 mm hexagon wrench, install the V– bank cover with the 2 cap nuts. HINT: For fixing the V – bank cover, push on the cover until sense of ”click” is felt. 10. INSTALL AIR CLEANER HOSE (a) Connect the air cleaner hose with the 2 hose clamps. (b) Connect the PCV hose. 11. CONNECT THROTTLE CABLE 12. CONNECT ACCELERATOR CABLE 13. FILL WITH ENGINE COOLANT Capacity: 8.7 liters (9.2 US qts. 7.7 Imp. qts) 14. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG2–258 1MZ–FE ENGINE – SFI SYSTEM FUEL TANK AND LINE COMPONENTS EG2–259 1MZ–FE ENGINE – SFI SYSTEM PRECAUTIONS 1. Always use new gaskets when replacing the fuel tank or component parts. 2. Apply the proper torque to all parts tightened. FUEL LINES AND CONNECTIONS INSPECTION (a) Check the fuel lines for cracks or leakage, and all connections for deformation. (b) Check the fuel tank vapor vent system hoses and connections for looseness, sharp bends or damage. (c) Check the fuel tank for deformation, cracks, fuel leak– age or tank band looseness. (d) Check the filler neck for damage or fuel leakage. (e) Hose and pipe connections are as shown in the illus– tration. If a problem is found, repair or replace the parts as necessary. EG2–260 1MZ–FE ENGINE – SFI SYSTEM MASS AIR FLOW (MAF) METER COMPONENTS FOR REMOVAL AND INSTALLATION EG2–261 1MZ–FE ENGINE – SFI SYSTEM MAF METER REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the Ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable Is discon– nected from the battery. 2. REMOVE AIR CLEANER NOSE (a) Disconnect the PCV hose. (b) Loosen the 2 hose clamps, and remove the air cleaner hose. 3. REMOVE MAP METER (a) Disconnect the MAF meter connector. (b) Remove the 2 bolts and MAF meter. MAF METER INSPECTION 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E2. Between terminals Resistance Temperature THA – E2 10–20k
– 20
C (–4
F) THA – E2 4 –7k
0
C (32
F) 20
C (68
F) THA – E2 2 –3k
0.9 – 1.3 k
40
C (104
F) THA = E2 0.4 – 0.7 k
60
C (140
F) THA – E2 If the resistance is not as specified, replace the MAF meter. EG2–262 1MZ–FE ENGINE – SFI SYSTEM 2. INSPECT MAF METER OPERATION (a) Connect the MAF meter connector. (b) Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative (–) tester probe to terminal E21. (c) Blow air into the MAF meter, and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. (d) Disconnect the MAF meter connector. MAF METER INSTALLATION (See Components for Removal and Installation) 1. INSTALL MAF METER (a) Insert the MAF meter end into the air cleaner case. (b) Install the MAF meter with the 2 bolts. Torque: 6.9 N–m (70 kgf–cm, 61 in.–Ibf) (c) Connect the MAF meter connector. 2. INSTALL AIR CLEANER HOSE (a) Install the air cleaner hose with the 2 hose clamps. (b) Connect the PCV hose. 3. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG2–263 1MZ–FE ENGINE – SFI SYSTEM THROTTLE BODY ON–VEHICLE INSPECTION 1. INSPECT THROTTLE BODY (a) Check that the throttle linkage moves smoothly. (b) Check the vacuum at each port. • Start the engine. • Check the vacuum with your finger. Port name At idle 3,000 rpm or more No vacuum Vacuum No vacuum Vacuum No vacuum Vacuum EG2–264 1MZ–FE ENGINE – SFI SYSTEM 2. INSPECT THROTTLE POSITION SENSOR (a) Apply vacuum to the throttle opener. (b) Disconnect the sensor connector. (c) Insert a thickness gauge between the throttle stop screw and stop lever. (d) Using an ohmmeter, measure the resistance between each terminal. Clearance between fever and stop screw Between terminals Resistance 0.28 – 6.4 k
0.35 mm (0.014 in.) VTA – E2 IDL – E2 0.70 mm (0.028 in.) IDL– E2 Infinity Throttle valve fully open VTA – E2 0 mm (0 in.) VC –E2 0.5 k
or less 2.0 – 11.6 k
2.7 – 7.7 k
(e) Reconnect the sensor connector. 3. INSPECT THROTTLE OPENER A. Warm up engine Allow the engine to warm up to normal operating temperature. B. Check idle speed Idle speed: 700 ± 50 rpm C. Check throttle opener setting speed (a) Disconnect the vacuum hose from the throttle opener, and plug the hose end. EG2–265 1MZ–FE ENGINE – SFI SYSTEM (b) Check the throttle opener setting speed. Throttle opener setting speed: 900–1,950 rpm If the throttle opener setting is not as specified, re– place the throttle body. (c) Stop the engine. (d) Reconnect the vacuum hose to the throttle opener. (e) Start the engine and check that the idle speed returns to the correct speed. EG2–266 1MZ–FE ENGINE – SFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION THROTTLE BODY REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. DRAIN ENGINE COOLANT 3. DISCONNECT ACCELERATOR CABLE 4. DISCONNECT THROTTLE CABLE EG2–267 1MZ–FE ENGINE – SFI SYSTEM 5. REMOVE AIR CLEANER HOSE (a) Disconnect the PCV hose. (b) Loosen the 2 hose clamps, and remove the air cleaner hose. 6. REMOVE THROTTLE BODY (a) Disconnect the throttle position sensor connector. (b) Disconnect the IAC valve connector. (c) Remove the hose clamp. (d) Disconnect the following vacuum hoses: (1) Vacuum hose (from charcoal canister) (2) Vacuum hose (from port R of EGR vacuum modulator) (3) Vacuum hose (from port E of EGR vacuum modulator) (4) Vacuum hose (from upper port of TVV) (5) Vacuum hose (from lower port of TVV) (e) Disconnect the following hoses: (1) Water bypass hose (from intake manifold) (2) Water bypass hose (from water inlet housing) (3) Air assist hose (f) Remove the 2 bolts, 2 nuts, EGR gas temperature sensor bracket, throttle body and gasket. EG2–268 1MZ–FE ENGINE – SFI SYSTEM THROTTLE BODY INSPECTION 1. CLEAN THROTTLE BODY (a) Using a soft brush and carburetor cleaner, clean the cast parts. (b) Using compressed air, clean all the passages and apertures. NOTICE: To prevent deterioration, do not clean the throt– tle position sensor. 2. INSPECT THROTTLE VALVE (a) Apply vacuum to the throttle opener. (b) Check that there is no clearance between the throttle stop screw and throttle lever when the throttle valve is fully closed. 3. INSPECT THROTTLE POSITION SENSOR (a) Apply vacuum to the throttle opener. (b) Insert a thickness gauge between the throttle stop screw and stop lever. (c) Using an ohmmeter, measure the resistance between each terminal. Clearance between lever and stop screw Between terminals Resistance 0 mm (0 in.) VTA –.E2 0.35 mm (0.014 in.) IDL – E2 0.5 k(
or less 0.70 mm (0.028 in.) IDL – E2 Infinity Throttle valve fully open VTA – E2 VC – E2 0.28 – 6.4 k
2.0 – 11.6 k
2.7 – 7.7 k
4. IF NECESSARY, ADJUST THROTTLE POSITION SENSOR (a) Loosen the 2 set screws of the sensor. EG2–269 1MZ–FE ENGINE – SFI SYSTEM (b) Apply vacuum to the throttle opener. (c) Insert a 0.54 mm (0.021 in.) thickness gauge, between the throttle stop screw and stop lever. (d) Connect the test probe of an ohmmeter to the termi– nals IDL and E2 of the sensor. (e) Gradually turn the sensor clockwise until the ohmme– ter deflects, and secure it with the 2 set screws. (f) Recheck the continuity between terminals IDL and E2. Clearance between lever and stop screw Continuity (IDL – E2) 0.35 mm (0.014 in.) Continuity 0.70 mm (0.028 in.) No continuity THROTTLE BODY INSTALLATION (See Components for Removal and Installation) 1. INSTALL THROTTLE BODY (a) Place a new gasket on the air intake chamber. (b) Install the throttle body, EGR gas temperature sensor bracket with the 2 bolts and 2 nuts. Torque: 19.5 N–m (200 kgf–cm, 14 ft–lbf) (c) Connect the following hoses: (1) Water bypass hose (from intake manifold) (2) Water bypass hose (from water inlet housing) (3) Air assist hose EG2–270 1MZ–FE ENGINE – SFI SYSTEM (d) Connect the following vacuum hoses: (1) Vacuum hose (from charcoal canister) (2) Vacuum hose (from port R of EGR vacuum modulator) (3) Vacuum hose (from port R of EGR vacuum modulator) (4) Vacuum hose (from upper port of TVV) (5) Vacuum hose (from lower port of TVV) (e) Install the hose clamp. (f) Connect the IAC valve connector. (g) Connect the throttle position sensor connector. 2. INSTALL AIR CLEANER HOSE (a) install the air cleaner hose with the 2 hose clamps. (b) Connect the PCV hose. 3. CONNECT THROTTLE CABLE 4. CONNECT ACCELERATOR CABLE 5. FILL WITH ENGINE COOLANT Capacity: 8.7 liters (9.2 US qts, 7.7 Imp.qts) 6. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG2–271 1MZ–FE ENGINE – SFI SYSTEM IDLE AIR CONTROL (IAC) VALVE ON–VEHICLE INSPECTION 1. INSPECT IAC VALVE OPERATION (a) Initial conditions: • Engine at normal operating temperature • Idle speed set correctly • Transmission in neutral position • A/C switch OFF (b) Using SST, connect terminals TE1 and E1 of the DLC 1. SST 09843–18020 (c) After engine speed are kept at approx. 1,000 rpm for 5 seconds, check that they return to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. EG2–272 1MZ–FE ENGINE – SFI SYSTEM (d) Remove the SST from the DLC1. SST 09843–18020 2. INSPECT IAC VALVE RESISTANCE (a) Disconnect the IAC valve connector. (b) Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO). Resistance: 19.3 – 22.3Ω at 20°C (68°F) If resistance is not as specified, replace the IAC valve. (c) Reconnect the IAC valve connector. 3. INSPECT AIR ASSIST SYSTEM (a) Initial conditions: • Engine at normal operating temperature • Idle speed set correctly • Transmission in neutral position • A/C switch OFF (b) Using SST, connect terminals TE1 and E1 of the DLC 1. SST 09843–18020 (c) After engine speed are kept at 900 – 1,300 rpm for 10 seconds, check that they return to idle speed. (d) Stop the engine. (e) Disconnect the air assist hose from the air pipe, and block off the IAC valve exit and the entry to the pipe. (f) Start the engine and check that the idle speed reaches 500 rpm or below (the engine may stall). If the idle does not reach 500 rpm or below, check for a leak between the air pipe and injector. EG2–273 1MZ–FE ENGINE – SFI SYSTEM (g) Remove the SST from the DLC 1. SST 09843–18020 (h) Reconnect the air assist hose to the air pipe. COMPONENTS FOR REMOVAL AND INSTALLATION EG2–274 1MZ–FE ENGINE – SFI SYSTEM IAC VALVE REMOVAL (See Components for Removal and Installation) 1. REMOVE THROTTLE BODY (See page EG2–266) 2. REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket. IAC VALVE INSPECTION INSPECT IAC VALVE OPERATION (a) Connect the positive (+) lead from the battery to terminal +B and negative (–) lead to terminal RSC, and check that the valve is closed. (b) Connect the positive (+) lead from the battery to terminal +B and negative (–) lead to terminal RSO, and check that the valve is open. If operation is not as specified, replace the IAC valve. IAC VALVE INSTALLATION (See Components for Removal and Installation) 1. INSTALL IAC VALVE (a) Place a new gasket on the throttle body. (b) Install the IAC valve with the 4 screws. 2. INSTALL THROTTLE BODY (See page EG2–269) EG2–275 1MZ–FE ENGINE – SFI SYSTEM ACOUSTIC CONTROL INDUCTION SYSTEM (ACIS) ON–VEHICLE INSPECTION INSPECT INTAKE AIR CONTROL VALVE (a) Using a 3–way connector, connect vacuum gauge to the actuator hose. (b) Start the engine. (c) While the engine is idling, check that the vacuum gauge needle does not move. (d) Rapidly depress the accelerator pedal to fully open position and check that the vacuum gauge needle momentarily fluctuates up to approx. 26.7 kPa (200 mmHg, 7.9 in.Hg). (The actuator rod is pulled out.) EG2–276 1MZ–FE ENGINE – SFI SYSTEM COMPONENTS FOR INTAKE AIR CONTROL VALVE REMOVAL AND INSTALLATION INTAKE AIR CONTROL VALVE REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. DISCONNECT HOSES FROM INTAKE AIR CONTROL VALVE (a) Disconnect the following hoses: (1) Brake booster vacuum hose (2) A/C idle–up air hose (3) Actuator vacuum hose (b) Disconnect the DLC1. EG2–277 1MZ–FE ENGINE – SFI SYSTEM 3. REMOVE INTAKE AIR CONTROL VALVE (a) Remove the 4 nuts and DLC1 bracket, and disconnect the 2 ground straps. (b) Remove the intake air control valve by prying a screw– driver between the intake air control valve and air intake chamber. (c) Remove the gasket. INTAKE AIR CONTROL VALVE AND COMPONENTS INSPECTION 1. INSPECT INTAKE AIR CONTROL VALVE (a) With 26.7 kPa (200 mmHg, 7.9 in.Hg) of vacuum applied to the actuator, check that the actuator rod moves. (b) One minute after applying the vacuum in (a), check that the actuator rod does not return. If the operation is not as specified, replace the intake air control valve. 2. INSPECT VACUUM TANK LOCATION: The LH side member under the battery tray. (a) Check that air flows from port B to port A. (b) Check that air does not flow from port A to port B. (c) Plug port B with your finger, and apply 26.7 kPa (200 mrnHg, 7.9 in.Hg) of vacuum to port A, and check that there is no change in vacuum after one minute. If the operation is not as specified, replace the vacuum tank. 3. INSPECT VSV (See page EG2–293) EG2–278 1MZ–FE ENGINE – SFI SYSTEM INTAKE AIR CONTROL VALVE INSTALLATION (See Components for Removal and Installation) 1. INSTALL INTAKE AIR CONTROL VALVE (a) Install a new gasket to the air intake chamber. (b) Apply a light coat of engine oil to the rubber portions. (c) Apply seal packing to the positions of the intake air control valve shown in the Seal packing: Part No.08826–00080 or equivalent illustration. (d) Install the intake air control valve, DLC 1 bracket and 2 ground straps with the 4 nuts. Torque: 14.5 N–m (145 kgf–cm, 10 ft–lbf) 2. CONNECT HOSES TO INTAKE AIR CONTROL VALVE (a) Connect the following hoses: (1) Brake booster vacuum hose (2) A/C idle–up air hose (3) Actuator vacuum hose (b) Install the DLC1. 3. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 4. CHECK FOR FUEL LEAKAGE (See page EG2–228) EG2–279 1MZ–FE ENGINE – SFI SYSTEM EFI MAIN RELAY EFI MAIN RELAY INSPECTION 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch Is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE EFI MAIN RELAY LOCATION: In the engine compartment relay box. 3. INSPECT EFI MAIN RELAY A. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. (b) Check that there is no continuity between terminals 3 and 5. If continuity is not as specified, replace the relay. B. Inspect relay operation (a) Apply battery voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY 5. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG2–280 1MZ–FE ENGINE – SFI SYSTEM CIRCUIT OPENING RELAY COMPONENTS FOR REMOVAL AND NOW INSTALLATION CIRCUIT OPENING RELAY INSPECTION (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch 1s turned to the ’LOCK’ position and the negative (–) terminal cable Is discon– nected from the battery. 2. REMOVE CIRCUIT OPENING RELAY 3. INSPECT CIRCUIT OPENING RELAY A. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals ST and E1. (b) Check that there is continuity between terminals +B and FC. (c) Check that there is no continuity between terminals + B and FP. If continuity is not as specified, replace the relay. EG2–281 1MZ–FE ENGINE – SFI SYSTEM B. Inspect relay operation (a) Apply battery voltage across terminals ST and El. M Using an ohmmeter, check that there is continuity between terminals +B and FP. If operation is not as specified, replace the relay. 4. REINSTALL CIRCUIT OPENING RELAY 5. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG2–282 1MZ–FE ENGINE – SFI SYSTEM ENGINE COOLANT TEMPERATURE (ECT) SENSOR ECT SENSOR INSPECTION 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. DRAIN ENGINE COOLANT 3. REMOVE ECT SENSOR (a) Disconnect the ECT sensor connector. (b) Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. 4. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the graph If the resistance is not as specified, replace the ECT sensor. 5. REINSTALL ECT SENSOR (a) Install a new gasket to the ECT sensor. (b) Using a 19 mm deep socket, install the ECT sensor. Torque: 20 N–m (200 kgf–cm, 14 ft–lbf) (c) Connect the ECT sensor connector. 6. REFILL WITH ENGINE COOLANT Capacity: 8.7 liters (9.2 US qts, 7.7 Imp. qts) 7. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG2–283 1MZ–FE ENGINE – SFI SYSTEM VSV FOR FUEL PRESSURE CONTROL ON–VEHICLE INSPECTION CHECK FUEL PRESSURE (See step 2 on page EG2–231) EG2–284 1MZ–FE ENGINE – SFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION EG2–285 1MZ–FE ENGINE – FE ENGINE – SFI SYSTEM VSV INSPECTION (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE V–BANK COVER Using a 5 mm hexagon wrench, remove the 2 cap nuts and V–bank cover. 3. REMOVE EMISSION CONTROL VALVE SET (See step 7 on page EG2–246) 4. REMOVE VSV (a) Disconnect the 2 vacuum sensing hoses from the VSV. (b) Remove the screw and VSV. 5. INSPECT VSV A. Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance: 33 – 39 Ω at 20
C (68
F) If there is no continuity, replace the VSV. B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. EG2–286 1MZ–FE ENGINE – FE ENGINE – SFI SYSTEM C. Inspect VSV operation (a) Check that the air flows from ports E to G. (b) Apply battery voltage across the terminals. (c) Check that the air flows from port E to the filter. If operation is not as specified, replace the VSV. 6. REINSTALL EMISSION CONTROL VALVE SET (See step 8 on page EG2–256) 7. REINSTALL VSV (a) Install the VSV with the screw. (b) Connect the 2 vacuum sensing hoses to the VSV. 8. REINSTALL V–BANK COVER Using a 5 mm hexagon wrench, install the V–bank cover with the 2 cap nuts. HINT: For fixing the V–bank cover, push on the cover until sense of ”click” is felt. 9. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG2–287 1MZ–FE ENGINE – SFI SYSTEM VSV FOR EGR ON–VEHICLE INSPECTION EGR SYSTEM INSPECTION (See steps 2 to 6 on pages EG2–207 and 208) EG2–288 1MZ–FE ENGINE – SFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION EG2–289 1MZ–FE ENGINE – SFI SYSTEM VSV INSPECTION (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the Ignition switch Is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE V–BANK COVER Using a 5 mm hexagon wrench, remove the 2 cap nuts and V – bank cover. 3. REMOVE EMISSION CONTROL VALVE SET (See step 7 on page EG2–246) 4. REMOVE VSV (a) Remove the filter. (b) Disconnect the 2 vacuum hoses from the VSV. (c) Remove the screw and VSV. 5. INSPECT VSV A. Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance: 33 – 39
at 20° C (68° F) If there is no continuity, replace the VSV. B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. 1MZ-FE ENGINE – -Memo EG2–291 1MZ–FE ENGINE – SFI SYSTEM VSV FOR ACIS ON–VEHICLE INSPECTION INSPECT INTAKE AIR CONTROL VALVE (See page EG2–275) EG2–292 1MZ–FE ENGINE – SFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION EG2–293 1MZ–FE ENGINE – SFI SYSTEM VSV INSPECTION (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE V – BANK COVER Using a 5 mm hexagon wrench, remove the 2 cap nuts and V–bank cover. 3. REMOVE EMISSION CONTROL VALVE SET (See step 7 on page EG2–246) 4. REMOVE VSV (a) Disconnect the 2 vacuum hoses from the VSV. (b) Remove the screw and VSV. 5. INSPECT VSV A. Inspect VSV for open circuit Using an ohmmeter, check that there is continuity between each terminals. Resistance: 33 – 39 Ω at 20°C (68°F) If there is no continuity, replace the VSV. B. Inspect VSV for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV. EG2–294 1MZ–FE ENGINE – SFI SYSTEM C. Inspect VSV operation (a) Check that air flows from pipe E to the filter. (b) Apply battery voltage across the terminals. (c) Check that air flows from pipe E to pipe F. If operation is not as specified, replace the VSV. 6. REINSTALL EMISSION CONTROL VALVE SET (See step 8 on page EG2–256) 7. REINSTALL VSV (a) Install the VSV with the screw. (b) Connect the 2 vacuum to the VSV. 8. REINSTALL V–BANK COVER Using a 5 mm hexagon wrench, install the V – bank cover with the 2 cap nuts. HINT: For fixing the V–bank cover, push on the cover until sense of ”click” is felt. 9. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG2–295 1MZ–FE ENGINE – SFI SYSTEM AC IDLE–UP VALVE ON–VEHICLE INSPECTION INSPECT A/C IDLE–UP VALVE OPERATION (a) Initial conditions: • Engine at normal operating temperature • Idle speed set correctly • Transmission in neutral position • A/C switch ON (b) Using SST, connect terminals TE1 and E1 of the DLC 1, check that idle–up occurs for approx. 3 seconds. SST 09843–18020 Valve operation is faulty if during the idle–up period the engine speed drops by 100 rpm or more, rough idle occurs, or the engine stalls. (c) Observe the idle speed for approx. 3 to 15 seconds. During this time the idle –up valve should go off, the IAC valve half –open and idle –up should occur. EG2–296 1MZ–FE ENGINE – FE ENGINE – SFI SYSTEM (d) Check that the idle speed after approx. 15 seconds, does not vary greatly from the idle speed observed in step (c). The idle–up valve should now be in ON position. If the idle speed is increases by more 100 rpm, using a 4 mm hexagon wrench, turn the idle–up valve adjustment screw to correct the idle–up valve. (e) Remove the SST from the DLC1. SST 09843–18020 (f) A/C switch OFF. EG2–297 1MZ–FE ENGINE – SFI SYSTEM A/C IDLE–UP VALVE INSPECTION 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch Is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE A/C IDLE–UP VALVE (a) Disconnect the idle–up valve connecter. (b) Disconnect the 2 air hoses. (c) Remove the 2 bolts and idle–up valve. 3. INSPECT A/C IDLE– UP VALVE A. Inspect idle–up valve for open circuit Using an ohmmeter, check that there is continuity between the terminals. Resistance: 30 – 33 Ω at 20°C (68°F) If there is no continuity, replace the idle–up valve. B. Inspect A/C idle–up valve for ground Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the idle–up valve. C. Inspect A/C idle–up valve operation (a) Check that the air does not flow from port E to port F. EG2–298 1MZ–FE ENGINE – SFI SYSTEM (b) Apply battery voltage across the terminals. (c) Check that the air flows from port E to port F. If operation is not as specified, replace the idle–up valve. 4. REINSTALL A/C IDLE– UP VALVE (a) Install the idle–up valve with the 2 bolts. (b) Connect the air hose. (c) Connect the idle–valve connector. 5. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG2–299 1MZ–FE ENGINE – SFI SYSTEM KNOCK SENSOR COMPONENTS FOR REMOVAL AND INSTALLATION EG2–300 1MZ–FE ENGINE – SFI SYSTEM KNOCK SENSORS INSPECTION (See Components for Removal and Installation) 1. REMOVE AIR INTAKE CHAMBER ASSEMBLY (See steps 1 to 10 on pages EG2–246 to 249) 2. DISCONNECT INJECTOR CONNECTORS 3. REMOVE INTAKE MANIFOLD ASSEMBLY (a) Disconnect the heater hose from the intake manifold. (b) Remove the 9 bolts, 2 nuts, 2 plates washers and intake manifold assembly. 4. REMOVE RH ENGINE MOUNTING STAY AND WATER OUTLET (a) Disconnect the following hoses and connectors: (1) Radiator inlet hose (2) Engine coolant reservoir hose (3) ECT sensor connector (4) ECT switch connector (5) Ground strap connector (b) Remove the 3 bolts and RH mounting stay. (c) Remove the wire band. (d) Disconnect the water bypass hose from the inlet hous– ing. (e) Remove the 2 bolts, 2 nuts, 2 plate washers and water outlet. EG2–301 1MZ–FE ENGINE – SFI SYSTEM (f) Remove the 2 gaskets. 5. REMOVE KNOCK SENSORS (a) Disconnect the knock sensor connector. (b) Remove the knock sensor. 6. INSPECT KNOCK SENSORS Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 7. REINSTALL KNOCK SENSORS (a) Install the knock sensor. Torque: 39 N–m (400 kgf–cm. 29 ft–lbf) (b) Connect the knock sensor connector. 8. REINSTALL WATER OUTLET AND RH ENGINE MOUNTING STAY (a) Install 2 new gaskets on the cylinder head. (b) Install the water outlet with the the 2 bolts, 2 plate washers and 2 nuts. Torque: 15 N–m (150 kgf–cm, 11 ft–lbf) NOTICE: Do not scratch the seal surface of the water outlet with the stud bolt. (c) Connect the water bypass hose to the inlet housing. (d) Install the wire band. (e) Install the RH mounting stay with the 3 bolts. Torque: 31.4 N–m (320 kgf–cm, 23 ft–lbf) EG2–302 1MZ–FE ENGINE – SFI SYSTEM (f) Connect the following hoses and connectors: (1) Radiator inlet hose (2) Engine coolant reservoir hose (3) ECT sensor connector (4) ECT switch connector (5) Ground strap connector 9. REINSTALL INTAKE MANIFOLD ASSEMBLY (a) Install the intake manifold assembly with the 9 bolts, 2 plate washers and 2 nuts. Torque: 15 N–m (150 kgf–cm, 11 ft–lbf) (b) Connect the heater hose to the intake manifold. 10. RECONNECT INJECTOR CONNECTORS 11. RETIGHTENING WATER OUTLET MOUNTING BOLTS AND NUTS Torque: 15 N–m (150 kgf–cm, 11 ft–lbf) 12. REINSTALL AIR INTAKE CHAMBER ASSEMBLY (See steps 5 to 14 on pages EG2–254 to 257) EG2–303 1MZ–FE ENGINE – SFI SYSTEM EGR GAS TEMPERATURE SENSOR EGR GAS TEMPERATURE SENSOR INSPECTION 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch Is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE NO.2 EGR PIPE Remove the 4 nuts, EGR pipe and 2 gaskets. 3. DISCONNECT EGR GAS TEMPERATURE SENSOR CONNECTOR AND CLAMP 4. REMOVE EGR VALVE AND VACUUM MODULATOR ASSEMBLY (a) Disconnect the following hoses: (1) Vacuum hose from port P of EGR vacuum modulator (2) Vacuum hose from port Q of EGR vacuum modulator (3) Vacuum hose from port R of EGR vacuum modulator (4) Vacuum hose from EGR valve (b) Remove the 3 nuts, EGR valve and vacuum modulator assembly and gasket. EG2–304 1MZ–FE ENGINE – SFI SYSTEM 5. REMOVE EGR GAS TEMPERATURE SENSOR 6. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 64 – 97 k
at 50
C (112
F) 11 – 16 k
et 100
C (212
F) 2 – 4 k
at 150
C (302
F) If the resistance is not as specified, replace the sensor. 7. REINSTALL EGR GAS TEMPERATURE SENSOR Torque: 20 N–m (200 kgf–cm, 14 ft–lbf) 8. REINSTALL EGR VALVE AND VACUUM MODULATOR ASSEMBLY (a) Install the EGR valve and vacuum modulator assembly with the 3 nuts. Torque: 12 N–m (120 kgf–cm, 9 ft–lbf) EG2–305 1MZ–FE ENGINE – FE ENGINE – SFI SYSTEM (b) Connect the following vacuum hoses: (1) Vacuum hose to port P of EGR vacuum modulator (2) Vacuum hose to port Q of EGR vacuum modulator (3) Vacuum hose to port R of EGR vacuum modulator (4) Vacuum to EGR valve 9. RECONNECT EGR GAS TEMPERATURE SENSOR CONNECTOR AND CLAMP 10. REINSTALL N0.2 EGR PIPE Install 2 new gaskets and the EGR pipe with the 4 nuts. Torque: 12 N–m (120 kgf–cm, 9 ft–lbf) 11. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG2–306 1MZ–FE ENGINE – SFI SYSTEM OXYGEN SENSOR OXYGEN SENSORS INSPECTION 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. INSPECT HEATER RESISTANCE OF MAIN HEATED OXYGEN SENSORS (a) Disconnect the oxygen sensor connectors. (b) Using an ohmmeter, measure the resistance between the terminals + B and HT. Resistance: 11 – 16Ω at 20
C (68
F) If the resistance is not as specified, replace the sensor. Torque: 44 N–m (450 kgf–cm, 31 ft–lbf) (c) Reconnect the oxygen sensor connectors. 3. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY EG2–307 1MZ–FE ENGINE – SFI SYSTEM Sub Heated Oxygen Sensor COMPONENTS FOR REMOVAL AND INSTALLATION EG2–308 1MZ–FE ENGINE – SFI SYSTEM OXYGEN SENSOR INSPECTION (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. INSPECT HEATER RESISTANCE OF SUB HEATED OXYGEN SENSOR (a) Remove the passenger’s seat. (b) Take out the consol box side of the floor carpet. (c) Disconnect the oxygen sensor connector. (d) Using an ohmmeter, measure the resistance between the terminals + B and HT. Resistance: 11 – 16
at 20
C (68
F) If the resistance is not as specified, replace the sensor. (e) Reconnect the oxygen sensor connector. (f) Reinstall the floor carpet. (g) Reinstall the passenger’s seat. 3. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 1MZ-FE ENGINE – -Memo EG2–310 1MZ–FE ENGINE – SFI SYSTEM FUEL CUT RPM FUEL CUT OFF INSPECTION 1. REMOVE V– BANK COVER Using a 5 mm hexagon wrench, remove the 2 cap nuts and V–bank cover. 2. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 3. CONNECT TACHOMETER TO ENGINE Connect the test probe of a tachometer to terminal IG (1) of the DLC1. NOTICE: • NEVER allow the tachometer terminal to touch ground as It could result in damage to the igniter and/or ignition coil. • As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of your until before use. 4. INSPECT FUEL CUT OFF PRM (a) Increase the engine speed to at least 3,500 rpm. (b) Use a sound scope to check for injector operating noise. (c) Check that when the throttle lever is released, injector operation noise stops momentarily and then resumes. HINT: Measure with the A/C OFF. Fuel return rpm: 1,200 rpm 5. DISCONNECT TACHOMETER 6. REINSTALL V–BANK COVER Using a 5 mm hexagon wrench, install the V– bank cover with the 2 cap nuts. HINT: For fixing the V– bank cover, push on the cover until sense of ”click” is felt. EG2–311 1MZ–FE ENGINE SERVICE SPECIFICATIONS SERVICE DATA Fuel pressure regulator Fuel pump Injector MAF meter Throttle body Throttle position sensor IAC valve VSV for Fuel pressure control VSV for ACIS VSV for EGR A/C idle–up valve ECT sensor EGR gas temperature sensor Main heated oxygen sensor Sub heated oxygen sensor Fuel cut rpm – SFI SYSTEM EG2–312 1MZ–FE ENGINE TORQUE SPECIFICATIONS Part tightened Fuel line (Union bolt type) Fuel line (Flare nut type for fuel pump side) Fuel line (Flare nut type for others) Fuel tank band x Body Fuel pump x Fuel tank Fuel pressure regulator x Delivery pipe Delivery pipe x Cylinder head No.1 fuel pipe x Intake manifold No.2 fuel pipe x Delivery pipe Air intake chamber x Intake manifold EGR pipe x EGR vacuum modulator EGR pipe x RH exhaust manifold No. 1 engine hanger x Air intake chamber Air intake chamber stay x Air intake chamber Ground stop x Intake air control valve Emission control valve set x Air intake chamber MAF meter x Air cleaner Throttle body x air intake chamber Intake air control valve x Air intake chamber ECT switch x Water outlet Knock sensor x Cylinder head Water outlet x Cylinder head RH engine mounting stay x Water outlet RH engine mounting stay x No.2 RH engine mounting bracket Intake manifold x Cylinder head EGR gas temperature sensor x EGR valve EGR valve x Air intake chamber Main heated oxygen sensor x Exhaust manifold Sub heated oxygen sensor x Exhaust pipe – SFI SYSTEM EG2–313 1MZ–FE ENGINE – COOLING SYSTEM COOLING SYSTEM DESCRIPTION This engine utilizes a pressurized forced circulation cooling system which includes a thermostat equipped with a bypass valve mounted on the inlet side. OPERATION EG2–314 1MZ–FE ENGINE – COOLING SYSTEM The cooling system is composed of the water jacket (inside the cylinder block and cylinder head), radiator, water pump, thermostat, electronically controlled hydraulic cooling fan, hoses and other components. Coolant which is heated in the water jacket is pumped to the radiator, through which a cooling fan blows air to cool the coolant as it passes through. Coolant which has been cooled is then sent back to the engine by the water pump, where it cools the engine. The water jacket is a network of channels in the shell of the cylinder block and cylinder head through which coolant passes. It is designed to provide adequate cooling of the cylinders and combustion chambers which become heated during engine operation. RADIATOR The radiator, mounted in the front of the vehicle, performs the function of cooling the coolant which has passed through the water jacket and become hot. The radiator consists of an upper tank and lower tank, and a core which connects the two tanks. The upper tank contains the inlet for coolant from the water jacket. The lower tank has an outlet and drain plug for the coolant. The core contains many tubes through which coolant flows from the upper tank to the lower tank as well as cooling fins which radiate heat away from the coolant in the tubes. The air sucked through the radiator by the cooling fan, as well as the wind generated by the vehicle’s travel, passes through the radiator, cooling the coolant. Models with an automatic transmission include an automatic transmission fluid cooler built into the lower tank of the radiator. A cooling fan is mounted behind the radiator to assist the flow of air through the radiator. When the coolant temperature is low, the fan operates slowly to help the engine warm up, and when the coolant temperature becomes high, the fan speed is increased to provide the air flow required for cooling. EG2–315 1MZ–FE ENGINE – COOLING SYSTEM RADIATOR CAP (on water outlet) The radiator cap is a pressure–type cap which seals the engine coolant circuit and the resulting pressurization of the engine as the coolant expands. The pressurization prevents the coolant from boiling even when the coolant temperature exceeds 100
C (212
F). A relief valve (pressurization valve) and a vacuum valve (negative pressure valve) are built into the radiator cap. The relief valve opens and lets steam escape through the overflow pipe when the pressure generated inside the cooling system exceeds the limit (coolant temperature: 110 – 120
C (230 – 248
F), pressure: 83 – 113 kPa (0.85 – 1.15 kgf/cm2,12.1 – 16.4 psi). The vacuum valve opens to alleviate the vacuum which develops in the coolant system after the engine is stopped and the coolant temperature drops. The valve’s opening allows the coolant in the reservoir tank to return to the cooling system. RESERVOIR TANK The reservoir tank is used to catch coolant which overflows the cooling system as a result of volumetric expansion when the coolant is heated. The coolant in the reservoir tank returns to the water outlet when the coolant temperature drops thus keeping the radiator full at all times and avoiding needless coolant loss. Check the reservoir tank level to learn if the coolant needs to be replenished. WATER PUMP The water pump is used for forced circulation of coolant through the cooling system. It is mounted on the front of the cylinder block and driven by a timing belt. THERMOSTAT The thermostat has a wax type bypass valve and is mounted in the water inlet housing. The thermostat includes a type of automatic valve operated by fluctuations in the coolant tempera– ture. This valve closes when the coolant temperature drops, preventing the circulation of coolant through the engine and thus permitting the engine to warm up rapidly. The valve opens when the coolant temperature has risen, allowing the circulation of coolant. Wax inside the thermostat expands when heated and contracts when cooled. Heating the wax thus generates pressure which overpowers the force of the spring which keeps the valve closed, thus opening the valve. When the wax cools, its contraction allows the force of the spring to take effect once more, closing the valve. The thermostat in this engine operates at a temperature of 82
C (180
F). ELECTRONICALLY CONTROLLED HYDRAULIC COOLING FAN (See page EG2–346) EG2–316 1MZ–FE ENGINE – FE ENGINE – COOLING SYSTEM PREPARATION SST (SPECIAL SERVICE TOOLS) 09230–01010 Radiator Service Tool Set 09249–63010 Torque Wrench Adaptor RH camshaft timing pulley 09620–30010 Steering Gear Box Replacer Set (09627–30010) Steering Sector Shaft Bushing Replacer (09631 –00020) Handle Hydraulic motor oil seal Hydraulic motor oil seal 09843–18020 Diagnosis Check Wire 09960–10010 Variable Pin Wrench Set (09962–01000) Variable Pin Wrench Arm Assy RECOMMENDED TOOLS 09025–00010 Smell Torque Wrench 09082–00050 TOYOTA Electrical Tester Set 09905–00013 Snap Ring Pliers For measuring preload EG2–317 1MZ–FE ENGINE – COOLING SYSTEM EQUIPMENT Caliper gauge Heater ECT sensor Precision straight edge Radiator cap tester Micrometer Thermometer ECT sensor Torque wrench Vernier calipers LUBRICANT Item Power steering fluid (Total) (Hydraulic cooling fan fluid) Capacity 2.2 liters (2.3 US qts, 1.9 Imp. qts) Classification ATF DEXRON
II COOLANT Item Engine coolant Capacity 8.7 liters (9.2 US qts, 7.7 Imp. qts) Classification Ethylene–glycol base EG2–318 1MZ–FE ENGINE – COOLING SYSTEM COOLANT CHECK 1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The engine coolant level should be between the ”LOW” and ”FULL” lines. If low, check for leaks and add engine coolant up to the ”FULL’ line. 2. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap from the water outlet. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) There should not be any excessive deposits of rust or scale around the radiator cap or water outlet filler hole, and the coolant should be free from oil. If excessively dirty, clean the coolant passages and replace the coolant. (c) Reinstall the radiator cap. EG2–319 1MZ–FE ENGINE – COOLING SYSTEM COOLANT REPLACEMENT 1. DRAIN ENGINE COOLANT (a) Remove the radiator cap from the water outlet. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) Loosen the drain cock (for the radiator) and drain plugs (for the engine), and drain the coolant. (c) Close the drain plugs and cock. Torque: 7 N–m (70 kgf–cm, 61 in.–lbf) for RH drain plug 13 N–m (130 kgf–cm, 9 ft–lbf) for LH drain plug 2. FILL ENGINE COOLANT (a) Slowly fill the system with coolant. • Use a good brand of ethylene–glycol base cool– ant and mix it according to the manufacturer’s directions. • Using coolant which includes more than 50% ethylene–glycol (but not more than 70 96) is recommended. NOTICE: • Do not use an alcohol type coolant. • The coolant should be mixed with demineralized water or distilled water. Capacity: 8.7 liters (9.2 US qts. 7.7 Imp. qts) (b) Install the radiator cap. (c) Start the engine, and bleed the cooling system. (d) If necessary, refill coolant into the reservoir tank up to the ”FULL” line. 3. CHECK ENGINE COOLANT FOR LEAKS EG2–320 1MZ–FE ENGINE – COOLING SYSTEM WATER PUMP COMPONENTS FOR REMOVAL AND INSTALLATION EG2–321 1MZ–FE ENGINE – COOLING SYSTEM EG2–322 1MZ–FE ENGINE – COOLING SYSTEM WATER PUMP REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. DRAIN ENGINE COOLANT 3. REMOVE TIMING BELT (See steps 2 to 20 on pages EG2–41 to 45) EG2–323 1MZ–FE ENGINE – COOLING SYSTEM 4. REMOVE CAMSHAFT TIMING PULLEYS (a) Using SST, remove the bolt and RH timing pulley. SST 09249–63010, 09960–10010 (09962–01000) (b) Using SST, remove the bolt and LH timing pulley. SST 09960–01000 (09962–01000) HINT: Arrange the camshaft timing pulleys (RH and LH sides). 5. REMOVE NO.2 IDLER PULLEY Remove the bolt and idler pulley. EG2–324 1MZ–FE ENGINE – COOLING SYSTEM 6. DISCONNECT ENGINE WIRE Disconnect the 3 clamps and engine wire from the No. 3 timing belt cover. 7. REMOVE NO.3 TIMING BELT COVER Remove the 6 bolts and belt cover. 8. REMOVE WATER PUMP Remove the 4 bolts, 2 nuts, water pump and gasket. WATER PUMP INSPECTION INSPECT WATER PUMP Turn the pulley and check that the water pump bear– ing moves smoothly and quietly. EG2–325 1MZ–FE ENGINE – COOLING SYSTEM WATER PUMP INSTALLATION (See Components for Removal and Installation) 1. INSTALL WATER PUMP Install a new gasket and the water pump with the 4 bolts and 2 nuts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) NOTICE: Do not get oil on the gasket. 2. INSTALL N0.3 TIMING BELT COVER . (a) Check that the timing belt cover gaskets have no cracks or peeling, etc. If the gaskets do have cracks or peeling, etc., replace them using the following steps. (1) Using a screwdriver and gasket scraper, remove all the old gasket material. (2) Thoroughly clean all components to remove all the loose material. (3) Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded black in the illustration. NOTICE: When joining gaskets, do not leave a gap be– tween them. Cut off any excess gasket. (4) After installing the gasket, press down on it so that the adhesive firmly sticks to the belt cover. (b) Install new gaskets to the No.3 belt cover. (c) Install the belt cover with the6 bolts. Torque: 8.5 N–m (85 kgf–cm, 74in.–Ibf) EG2–326 1MZ–FE ENGINE – FE ENGINE – COOLING SYSTEM 3. CONNECT ENGINE WIRE Connect the engine wire with the 3 clamps. 4. INSTALL N0.2 IDLER PULLEY (a) Install the idler pulley with the bolt. Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) (b) Check that the idler pulley moves smoothly. 5. INSTALL RH CAMSHAFT TIMING PULLEY (a) Install the timing pulley, facing the flange side out– ward. (b) Align the knock pin hole of the camshaft with the knock pin groove of the timing pulley as shown. (c) Using SST, install and torque the bolt. SST 09249–63010, 09960–10010 (09962–01000) Torque: 88 N–m (900 kgf–cm, 65 ft–lbf) HINT: Use a torque wrench with a fulcrum length of 340 mm (13.39 in.) EG2–327 1MZ–FE ENGINE – COOLING SYSTEM 6. INSTALL LH CAMSHAFT TIMING PULLEY (a) Install the timing pulley, facing the flange side inward. (b) Align the knock pin hole of the camshaft with the knock pin groove of the timing pulley as shown. (c) Using SST, install and torque the bolt. SST 09960–10010 (09962–01000) Torque: 125 N–m (1,300 kgf–cm, 94 ft–lbf) 7. INSTALL TIMING BELT (See steps6 to 27 on pages EG2–51 to 56) 8. FILL WITH ENGINE COOLANT Capacity: 8.7 liters (9.2 US qts, 7.7 Imp. qts) 9. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 10. START ENGINE AND CHECK FOR LEAKS 11. RECHECK ENGINE COOLANT LEVEL EG2–328 1MZ–FE ENGINE – COOLING SYSTEM THERMOSTAT COMPONENTS FOR REMOVAL AND INSTALLATION THERMOSTAT REMOVAL (See Components for Removal and Installation) HINT: Removal of the thermostat would have an ad– verse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat. 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the Ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. DRAIN ENGINE COOLANT EG2–329 1MZ–FE ENGINE – COOLING SYSTEM 3. REMOVE AIR CLEANER CAP, VOLUME AIR FLOW METER AND AIR CLEANER HOSE (a) Disconnect the volume air flow meter connector and wire clamp. (b) Disconnect the accelerator cable clamp. (c) Disconnect the PCV hose. (d) Loosen the air cleaner hose clamp bolt. (e) Disconnect the 4 air cleaner cap clips. (f) Remove the air cleaner cap and volume air flow meter together with the air cleaner hose. 4. DISCONNECT HEATER HOSE 5. DISCONNECT PRESSURE HOSE OF HYDRAULIC MOTOR Remove the bolt and disconnect the pressure hose from the water inlet. 6. DISCONNECT ENGINE WIRE Remove the 2 nuts and disconnect the engine wire from the water inlet and cylinder head. 7. DISCONNECT ENGINE COOLANT TEMPERATURE (ECT) SENSOR CONNECTOR 8. DISCONNECT WATER INLET PIPE (a) Remove the bolt holding the water inlet pipe to the cylinder head. (b) Disconnect the water inlet pipe and remove the 0– ring. EG2–330 1MZ–FE ENGINE – COOLING SYSTEM 8. REMOVE WATER INLET Remove the 3 nuts and water inlet from the water inlet housing. 10. REMOVE THERMOSTAT AND GASKET THERMOSTAT INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. (a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80 – 84°C (176 – 183°F) If the valve opening temperature is not as specified, replace the thermostat. (c) Check the valve lift. Volvo lift: 10.0 mm (0.394 In.) or more at 95° C (203
F) If the valve lift is not as specified, replace the thermo– stat. (d) Check that the valve spring is tight when the thermo– stat is fully closed. If not closed, replace the thermostat. EG2–331 1MZ–FE ENGINE – COOLING SYSTEM THERMOSTAT INSTALLATION (See Components for Removal and Installation) 1. PLACE THERMOSTAT IN WATER PUMP (a) Install a new gasket to the thermostat. (b) Align the jiggle valve of the thermostat with stud bolt (A), and insert the thermostat in the water inlet hous– ing. HINT: The jiggle valve may be set within 30
of either side of the prescribed position. 2. INSTALL WATER INLET Install the water inlet with the 3 nuts. Torque: 8 N–m (80 kgf–cm, 69 in.–Ibf) 3. INSTALL WATER INLET PIPE (a) Install a new 0 – ring to the water inlet pipe. (b) Apply soapy water to the 0 – ring. (c) Connect the water inlet pipe to the water inlet. (d) Install the bolt holding the water inlet pipe to the cylinder head. Torque: 19.5 N–m (200 kgf–cm, 14 ft–lbf) EG2–332 1MZ–FE ENGINE – COOLING SYSTEM 4. CONNECT ENGINE COOLANT TEMPERATURE SENSOR (ECT) CONNECTOR 5. CONNECT ENGINE WIRE Connect the engine wire to the water inlet and cylin– der head with the 2 nuts. 6. CONNECT HYDRAULIC MOTOR PRESSURE HOSE Connect the pressure hose with the bolt. Torque: 8 N–m (80 kgf–cm, 69 in.–Ibf) 7. CONNECT HEATER HOSE 8. REINSTALL AIR CLEANER CAP, VOLUME AIR FLOW METER AND AIR CLEANER HOSE (a) Connect the air cleaner hose, and install the air clean– er cap and volume air flow meter with the 4 clips. (b) Tighten the air cleaner hose clamp bolt. (c) Connect the PCV hose. (d) Connect the accelerator cable clamp. (e) Connect the volume air flow meter connector and wire clamp. 9. FILL WITH ENGINE COOLANT Capacity: 8.7 liters (9.2 US qts, 7.7 Imp. qts) 10. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 11. START ENGINE AND CHECK FOR LEAKS 12. RECHECK ENGINE COOLANT LEVEL EG2–333 1MZ–FE ENGINE – COOLING SYSTEM RADIATOR RADIATOR CLEANING Using water or a steam cleaner, remove any mud and dirt from the radiator core. NOTICE: If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. If the cleaner nozzle pressure is 2,942 – 3,432 kPa (30 – 35 kgf/cm2, 427 – 498 psi), keep a distance of at least 40 cm (15.75 in.) between the radiator core and cleaner nozzle. RADIATOR INSPECTION 1. REMOVE RADIATOR CAP FROM WATER OUTLET CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. 2. INSPECT RADIATOR CAP NOTICE: When performing steps (a) and (b) below, keep the radiator pump tester at an angle of over 30
above the horizontal. (a) Using a radiator cap tester, slowly pump the tester and check that air is coming from the relief valve. Pump speed: 1 push/3 seconds or more NOTICE: Push the pump at a constant speed. If air is not coming from the relief valve, replace the radiator cap. (b) Pump the tester several times and measure the relief valve opening pressure. Pump speed: 1 at time 1 push/1 second or less 2nd time or more Any speed Standard opening pressure: 83 – 113 kPa (0.85 – 1.15 kgf/cm2, 12.1 – 16.4 psi) Minimum opening pressure: 69 kPa (0.7 kgf/cm2, 10.0 psi) If the opening pressure is less than minimum, replace the radiator cap. EG2–334 1MZ–FE ENGINE – COOLING SYSTEM 3. INSPECT COOLING SYSTEM FOR LEAKS (a) Fill the radiator and engine with coolant and attach a radiator cap tester. (b) Warm up the engine. (c) Pump it to 127 kPa (1.3 kgf/cm2, 18.5 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head. 4. REINSTALL RADIATOR CAP EG2–335 1MZ–FE ENGINE – COOLING SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION EG2–336 1MZ–FE ENGINE – COOLING SYSTEM RADIATOR REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. DRAIN ENGINE COOLANT 3. DISCONNECT PRESSURE HOSE Remove the union bolt and gasket, and disconnect the pressure hose from the hydraulic motor. NOTICE: Catch leaking oil in a container. 4. DISCONNECT UPPER RADIATOR HOSE 5. DISCONNECT HYDRAULIC MOTOR RETURN HOSE 6. DISCONNECT LOWER RADIATOR HOSE FROM WATER INLET PIPE 7. DISCONNECT OIL COOLER HOSES FROM OIL COOLER PIPES Disconnect the 2 hoses. 8. Canada only: REMOVE NO.7 RELAY BLOCK EG2–337 1MZ–FE ENGINE – COOLING SYSTEM 9. DISCONNECT CRUISE CONTROL ACTUATOR WIRE CLAMP 10. REMOVE RADIATOR AND HYDRAULIC COOLING FAN (a) Remove the 2 bolts and 2 upper supports. (b) Lift out the radiator. 11. REMOVE A/T OIL COOLER HOSES Remove the 2 hoses. 12. REMOVE RADIATOR LOWER HOSE 13. REMOVE HYDRAULIC COOLING FAN FROM RADIATOR Remove the 6 bolts and cooling fan. 14. REMOVE LOWER RADIATOR SUPPORTS Remove the 2 lower radiator supports. EG2–338 1MZ–FE ENGINE – COOLING SYSTEM COMPONENTS FOR DISASSEMBLY AND ASSEMBLY RADIATOR DISASSEMBLY (See Components for Disassembly and Assembly) ASSEMBLY OF SST 09230 – 01010 (a) Install the claw to the overhaul handle, inserting it in the hole in part ”A” as shown in the diagram. (b) While gripping the handle, adjust the stopper bolt so that dimension ”B” shown in the diagram is 0.2–0.5 mm (0.008–0.020 in.). NOTICE: If this adjustment is not performed, the claw may be damaged. EG2–339 1MZ–FE ENGINE – COOLING SYSTEM 2. UNCAULK LOCK PLATES Using SST to release the caulking, squeeze the handle until stopped by the stopper bolt. SST 09230 – 01010 3. REMOVE TANKS AND O–RINGS (a) Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a soft–faced hammer and remove the tank. (b) Remove the O–ring. 4. REMOVE OIL COOLER FROM LOWER TANK (a) Remove the pipes. HINT: Make a note of the direction to face the pipes. (b) Remove the nuts, and plate washers. (c) Remove the oil cooler and 0–rings. RADIATOR ASSEMBLY (See Components for Disassembly and Assembly) 1. INSTALL OIL COOLER TO LOWER TANK (a) Clean the O–ring contact surface of the lower tank and oil cooler. (b) Install new 0–rings (1) to the oil cooler (2). (c) Install the oil cooler with the 0–rings to the lower tank (3). (d) Install the plate washers (4), and nuts (5). Torque the nuts. Torque: 8.3 N–m (85 kgf–cm, 74 ft–lbf) (e) Install the pipes (6). Torque: 14.7 N–m (150 kgf–cm, 11 ft–lbf) HINT: Face the pipes in the same direction as before disassembly. EG2–340 1MZ–FE ENGINE – COOLING SYSTEM 2. INSPECT LOCK PLATE Inspect the lock plate for damage. HINT: • If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible. • Therefore, first correct any deformation with pliers or similar object. Water leakage will result if the bottom of the lock plate groove is damaged or dented, Therefore, repair or replace if neces– sary. 3. INSTALL NEW O–RINGS AND TANKS (a) After checking that there are no foreign objects in the lock plate groove, install the new 0–ring without twisting it. HINT: When cleaning the lock plate groove, lightly rub it with sand paper without scratching it. (b) Install the tank without damaging the 0 – ring. (c) Tap the lock plate with a soft–faced hammer so that there is no gap between it and the tank. 4. ASSEMBLY OF SST SST 09230 – 01010 (a) Install the punch assembly to the overhaul handle, inserting it in the hole in part ”A” as shown in the illustration. (b) While gripping the handle, adjust the stopper bolt so that dimension ”B” shown in the diagram is 7.7 mm (0.30 in.). 5. CAULK LOCK PLATE (a) Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by squeezing the handle until stopped by the stopper plate. SST 09230 – 01010 EG2–341 1MZ–FE ENGINE – COOLING SYSTEM HINT: • Do not stake the areas protruding around the pipes, brackets or tank ribs. • The points shown in the illustration and oil cooler near here cannot be staked with the SST. Use a plier or similar object and be careful not to damage the core plates. (b) Check the lock plate height (H) after completing the caulking. Plate height: 7.75 – 8.25 mm (0.305 – 0.325 in.) If not within the specified height, adjust the stopper bolt of the handle again and perform the caulking again. 6. PAINT LOCK PLATES EG2–342 1MZ–FE ENGINE – COOLING SYSTEM RADIATOR INSTALLATION (See Components for Removal and Installation) 1. INSTALL RADIATOR SUPPORTS Install the 2 supports. 2. INSTALL HYDRAULIC COOLING FAN TO RADIATOR Install the cooling fan with the6 bolts. Torque: 4.9 N–m (50 kgf–cm, 43 in.–Ibf) 3. INSTALL RADIATOR LOWER HOSE 4. INSTALL A/T OIL COOLER HOSES Install the 2 hoses. 6. INSTALL RADIATOR AND HYDRAULIC COOLING FAN Place the radiator in position, and install the 2 upper supports with the 2 bolts. Torque: 12.8 N–m (130 kgf–cm, 9 ft–lbf) HINT: After installation, check that the rubber cushion (A) of the support is not depressed. 6. CONNECT CRUISE CONTROL ACTUATOR WIRE CLAMP EG2–343 1MZ–FE ENGINE – COOLING SYSTEM 7. Canada only: INSTALL NO.7 RELAY BLOCK 8. CONNECT OIL COOLER HOSES 9. CONNECT LOWER RADIATOR HOSE 10. CONNECT HYDRAULIC MOTOR RETURN HOSE 11. CONNECT UPPER RADIATOR HOSE 12. CONNECT PRESSURE HOSE TO HYDRAULIC MOTOR Connect the pressure hose with a new gasket and the union bolt. Torque: 63.7 N–m (650 kgf–cm, 47 ft–lbf) 13. FILL WITH ENGINE COOLANT Capacity: 8.7 liters (9.2 US qts, 7.7 Imp. qts) 14. FILL COOLING FAN (PS) RESERVOIR TANK WITH FLUID 15. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 16. START ENGINE AND CHECK FOR LEAKS EG2–344 1MZ–FE ENGINE – COOLING SYSTEM 17. BLEED ELECTRONICALLY CONTROLLED HYDRAULIC COOLING FAN SYSTEM (See page EG2–348) 18. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL NOTICE: Do not overfill. 19. RECHECK ENGINE COOLANT LEVEL EG2–345 1MZ–FE ENGINE – COOLING SYSTEM ELECTRONICALLY CONTROLLED HYDRAULIC COOLING FAN SYSTEM Description In this system, the cooling fan ECU controls the hydraulic pressure acting on the hydraulic motor, thus controlling the speed of the cooling fan steplessly in response to the condition of the engine and air conditioning. System Circuit EG2–346 1MZ–FE ENGINE – COOLING SYSTEM Operation The hydraulic pump is integrated with the PS pump and is driven by a drive belt. The solenoid valve adjusts the volume of oil sent from the hydraulic pump to the hydraulic motor which drive; the fan directly, thereby controlling the fan speed. Oil which has passed through the hydraulic motor is cooled by the oil cooler before returning to the PS pump reservoir tank. The solenoid valve is controlled by the cooling fan ECU in accordance with the engine rpm, engine coolant temperature and A/C signals. EG2–347 1MZ–FE ENGINE – COOLING SYSTEM On–Vehicle Inspection FLUID LEVEL INSPECTION 1. KEEP VEHICLE LEVEL 2. INSPECT FLUID LEVEL (a) Using SST, connect terminals OP1 and E1 of the data link connector 1. SST 09843–18020 HINT: When terminals OP1 and E1 are connected, the circuit of the ECT sensor is grounded, fixing the cool– ing fan speed at approx. 1,100 rpm. (Fail–safe opera– tion occurs.) (b) Keep the engine speed at 2,000 rpm until the fluid temperature reaches the specified temperature. Fluid temperature: 70 – 90°C (158 – 195°F) (c) Check that there is no foaming and emulsification of the fluid in the reservoir tank. (d) Measure the fluid level with the engine running. (e) Stop the engine, and measure the fluid level. (f) Subtract level (d) from (e). Maximum level difference: 5 mm (0.20 in.) (g) Check the fluid level. If low, add fluid. Fluid: ATF DEXRON
II HINT: Check that fluid level is within the ”HOT” level on reservoir tank. If the fluid is cold, check that it is within the ”COLD” level on the reservoir tank. (h) Remove the SST from the data link connector 1. SST 09843–18020 EG2–348 1MZ–FE ENGINE – COOLING SYSTEM HYDRAULIC COOLING FAN SYSTEM BLEEDING 1. CHECK FLUID LEVEL IN RESERVOIR TANK If low, add fluid. Fluid: ATF DEXRON
II HINT: Check that fluid level is within the ”HOT” level on reservoir tank. If the fluid is cold, check that it is within the ”COLD” level on the reservoir tank. 2. BLEED COOLING SYSTEM (a) Using SST, connect terminals OP1 and E1 of the data link connector 1. SST 09843–18020 HINT: When terminals OP1 and E1 are connected, the circuit of the ECT sensor is grounded, fixing the cool– ing fan speed at approx. 1,100 rpm. (Fail–safe opera– tion occurs.) (b) Start the engine without depressing the accelerator pedal. (c) Leave the engine running for several seconds. (d) Check that there is no foaming and emulsification of the fluid in the reservoir tank. (e) Remove the SST from the data link connector 1. SST 09843–18020 EG2–349 1MZ–FE ENGINE – COOLING SYSTEM OIL PRESSURE INSPECTION 1. DISCONNECT PRESSURE HOSE FROM HYDRAULIC MOTOR, AND INSTALL OIL PRESSURE GAUGE (a) Remove the union bolt and gasket, and disconnect the pressure hose from the hydraulic motor. (b) Connect the gauge side of a pressure gauge to pres– sure hose, and the valve side to the hydraulic motor. 2. INSPECT OIL PRESSURE HINT: Before inspecting the oil pressure, first check that the A/C is off. (a) Using SST, connect terminals OP1 and E1 of the data link connector 1. SST 09843–18020 HINT: When terminals OP1 and E1 are connected, the circuit of the ECT sensor is grounded, fixing the cool– ing fan speed at approx. 1,100 rpm. (Fail–safe opera– tion occurs.) (b) Bleed the hydraulic cooling system. (See page EG2–348) (c) Keep the engine speed at 2,000 rpm until the fluid temperature reaches the specified temperature. Fluid temperature: 70 – 90 C (158 – 195 F) (d) Check the fluid level is correct. EG2–350 1MZ–FE ENGINE – FE ENGINE – COOLING SYSTEM (e) Measure the oil pressure at idling. Oil pressure: 981 – 1,961 kPa (10 – 20 kgf/cm2, 142 – 284 pal) (f) Remove the SST from the data link connector 1. SST 09843–18020 (g) Check that the oil pressure decreases. 3. REMOVE OIL PRESSURE GAUGE, AND RECONNECT PRESSURE HOSE TO HYDRAULIC MOTOR (a) Remove the pressure gauge. (b) Connect the pressure hose to the hydraulic motor with a new gasket and the union bolt. Torque: 63.7 N–m (650 kgf–cm, 47 ft–lbf) Hydraulic Pump (PS pump) (See SR section) EG2–351 1MZ–FE ENGINE – COOLING SYSTEM Hydraulic Motor COMPONENTS FOR REMOVAL AND INSTALLATION EG2–352 1MZ–FE ENGINE – COOLING SYSTEM HYDRAULIC MOTOR REMOVAL (See Components for Removal and Installation) 1. REMOVE RADIATOR (See page EG2–336) 2. REMOVE HYDRAULIC COOLING FAN Remove the 6 bolts and hydraulic cooling fan. 3. REMOVE COOLING FAN FROM HYDRAULIC MOTOR Loosen the fan mounting nut clockwise, and remove the nut, plate washer and fan. 4. REMOVE HYDRAULIC MOTOR FROM FAN SHROUD Remove the 3 bolts and hydraulic motor. EG2–353 1MZ–FE ENGINE – COOLING SYSTEM COMPONENTS FOR DISASSEMBLY AND ASSEMBLY HYDRAULIC MOTOR DISASSEMBLY (See Components for Disassembly and Assembly) 1. MOUNT MOTOR HOUSING Carefully mount the motor housing in a vise. NOTICE: Be careful not to damage the motor housing. 2. REMOVE MOTOR COVER (a) Remove the 4 bolts and motor cover. (b) Remove the 0–ring from the motor housing. 3. REMOVE REAR THRUST WASHER 4. REMOVE DRIVE SHAFT EG2–354 1MZ–FE ENGINE – COOLING SYSTEM 5. REMOVE DRIVE AND DRIVEN ROTORS 6. REMOVE FRONT THRUST WASHER HYDRAULIC MOTOR INSPECTION 1. INSPECT DRIVE AND DRIVEN ROTORS (a) Install the drive and driven rotors to the motor hous– ing with the dot mark facing upward. (b) Using a feeler gauge and precision straight edge, mea– sure the side clearance between the rotor and preci– sion straight edge. Standard side clearance: 0.01 – 0.04 mm (0.0004 – 0.0016 in.) Maximum side clearance: 0.05 mm (0.0020 in.) If the clearance is greater than maximum, replace the rotors as a set. If necessary, replace the motor assem– bly. HINT: When replacing the rotors, select a new rotor set according to the imprinted mark on the motor housing. Imprinted mark on housing Rotor set 16906–50010 16906–50020 16906–50030 EG2–355 1MZ–FE ENGINE – COOLING SYSTEM 2. INSPECT CLEARANCE OF DRIVE SHAFT (a) Using a caliper gauge, measure the, shaft hole inside diameter of the housing and cover. Shaft hole inside diameter: 14.000 – 14.011 mm (0.5512 – 0.5516 in.) (b) Using a micrometer, measure the drive shaft diameter. Shaft diameter: 13.973 – 13.984 mm (0.5501 – 0.5506 in.) (c) Subtract the drive shaft diameter measurement from the shaft hole diameter measurement. Standard clearance: 0.016 – 0.038 mm (0.0006 – 0.0015 in.) Maximum clearance: 0.04 mm (0.0016 In.) If the clearance is greater than maximum, replace the shaft. If necessary, replace the motor assembly. EG2–356 1MZ–FE ENGINE – FE ENGINE – COOLING SYSTEM OIL SEAL REPLACEMENT 1. REMOVE OIL SEAL (a) Using snap ring pliers, remove the snap ring and plate washer. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the housing. 2. INSTALL OIL SEAL (a) Using SST and a hammer, tap in a new oil seal to a depth of 4.5 – 5.5 mm (0.177 – 0.217 in.) from the housing edge. SST 09620–30010 (09627–30010, 09631– 00020) (b) Using snap ring pliers, install the plate washer and snap ring. (c) Apply fluid to the oil seal lip. EG2–357 1MZ–FE ENGINE – COOLING SYSTEM HYDRAULIC MOTOR ASSEMBLY (See Components for Disassembly and Assembly) HINT: • Thoroughly clean all parts to be assembled. • Before installing the parts, apply new fluid to all sliding and rotating surfaces. 1. MOUNT MOTOR HOUSING Slightly mount the motor housing in a vise. NOTICE: Be careful not to damage the motor housing. 2. INSTALL FRONT THRUST WASHER 3. INSTALL DRIVEN AND DRIVE ROTORS Install the drive and driven rotors with the dot mark facing upward. 4. INSTALL DRIVE SHAFT 5. INSTALL REAR THRUST WASHER 6. INSTALL MOTOR COVER (a) Install a new 0–ring to the motor housing groove. (b) Install the motor cover with the 4 bolts. Torque: 28 N–m (290 kgf–cm, 21 ft–lbf) EG2–358 1MZ–FE ENGINE – COOLING SYSTEM 7. INSPECT DRIVE SHAFT PRELOAD (a) Check that the drive shaft rotates smoothly without abnormal noise. (b) Temporarily install the pulley nut, and check the rotat– ing torque. Rotating torque: 0.3 N–m (3.0 kgf–cm, 2.6 in.–lbf) HYDRAULIC MOTOR INSTALLATION (See Components for Removal and Installation) 1. INSTALL HYDRAULIC MOTOR TO FAN SHROUD Install the hydraulic motor with the 3 bolts. Torque: 4.9 N–m (50 kgf–cm. 43 in.–lbf) 2. INSTALL COOLING FAN TO HYDRAULIC MOTOR Install the fan with the plate washer and nut. Tighten the nut by turning it counterclockwise. Torque: 15 N–m (150 kgf–cm, 11 ft–lbf) 3. INSTALL HYDRAULIC COOLING FAN Install the hydraulic cooling fan with the6 bolts. Torque: 4.9 N–m (50 kgf–cm, 43 In.–Ibf) 4. INSTALL RADIATOR (See page EG2–342) EG2–359 1MZ–FE ENGINE – FE ENGINE – COOLING SYSTEM Oil Cooler COMPONENTS FOR REMOVAL AND INSTALLATION OIL COOLER REMOVAL (See Components for Removal and Installation) 1. REMOVE UPPER RADIATOR SEAL Remove the 12 clips and radiator seal. 2. REMOVE RADIATOR GRILLE Remove the 2 mounting screws and radiator grille. EG2–360 1MZ–FE ENGINE – COOLING SYSTEM 3. REMOVE RH PARKING LIGHT ASSEMBLY (a) Remove the screw. (b) Disconnect the connector and remove the parking light assembly. 4. REMOVE RH HEADLIGHT ASSEMBLY (a) Remove the 3 bolts and nut. (b) Disconnect the 2 connectors and remove the head– light assembly. 5. DISCONNECT HOSES FROM OIL COOLER Disconnect the following hoses: (1) Outlet hose (to reservoir tank) (2) Inlet hose (from hydraulic motor) 6. REMOVE UNDERCOVER 7. REMOVE OIL COOLER (a) Pull aside the shroud to expose the bolt in the stay. Remove the bolt. (b) Remove the 2 nuts and remove the oil cooler. EG2–361 1MZ–FE ENGINE – COOLING SYSTEM OIL COOLER INSPECTION INSPECT OIL COOLER Check the oil cooler for damage or clogging. If necessary, replace the oil cooler. OIL COOLER INSTALLATION (See Components for Removal and Installation) 1. INSTALL OIL COOLER (a) Install the oil cooler with the 2 nuts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) (b) Install the bolt while pulling aside the shroud. 2. INSTALL UNDERCOVER 3. CONNECT HOSES TO OIL COOLER Connect the following hoses: (1) Outlet hose (to reservoir) (2) Inlet hose (from hydraulic motor) 4. INSTALL RH HEADLIGHT ASSEMBLY (a) Connect the 2 connectors. (b) Install the headlight assembly with the 3 bolts and nut. EG2–362 1MZ–FE ENGINE – COOLING SYSTEM 5. INSTALL RH PARKING LIGHT ASSEMBLY (a) Connect the connector. (b) Install the parking light assembly with the screw. 6. INSTALL RADIATOR GRILLE Install the radiator grille with the 2 mounting screws. 7. INSTALL UPPER RADIATOR SUPPORT SEAL Install the support seal with the 12 clips. 8. FILL PS RESERVOIR TANK WITH FLUID (See page EG2–347) 9. BLEED ELECTRONICALLY CONTROLLED HYDRAULIC COOLING FAN SYSTEM (See page EG2–348) EG2–363 1MZ–FE ENGINE – COOLING SYSTEM Cooling Fan ECU COMPONENTS FOR REMOVAL AND INSTALLATION COOLING FAN ECU INSPECTION 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. DISCONNECT COOLING FAN ECU CONNECTOR (See Components) (a) Remove the instrument panel undercover. (b) Remove the instrument lower panel. (c) Remove the glove compartment door. (d) Remove the glove compartment. (e) Disconnect the cooling fan ECU connector. EG2–364 1MZ–FE ENGINE – FE ENGINE – COOLING SYSTEM 3. INSPECT COOLING FAN ECU (a) Connect the cable to the negative (–) terminal of the battery. (b) Check the connector on the wiring harness side as shown in the chart. Check for Condition Tester connection Specified value Voltage 1 – Ground Ignition switch ON Battery voltage Resistance 2–3 Solenoid valve at cold (25°C (77°F) ) 7.6 – 8.0
Continuity 4 – Ground Continuity 5 – Ground Continuity Resistance Continuity Throttle valve open No continuity Throttle valve closed Continuity A/C pressure SW connector disconnected No continuity A/C pressure SW connector connected Continuity Coolant temperature at 80°C (176°F) 1.48 – 1.58 k
8 – Ground 9–10 (c) Disconnect the cable from the negative (–) terminal of the battery. 4. RECONNECT COOLING FAN ECU CONNECTOR 5. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY ECT SENSOR INSPECTION INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 1.48 – 1.58 Ω at 80° C (176° F) If the resistance is not as specified, replace the sensor. EG2–365 1MZ–FE ENGINE – COOLING SYSTEM A/C High –Pressure Switch A/C HIGH–PRESSURE SWITCH INSPECTION 1. DISCONNECT A/C HIGH–PRESSURE SWITCH CONNECTOR 2. INSTALL MANIFOLD GAUGE SET (See page AC–23) 3. INSPECT A/C HIGH–PRESSURE SWITCH (a) When the A/C switch is OFF, check that there is continuity between terminals 2 and 3. (When the pressure is 1,226 kPa (12.5 kgf/cm2, 178 psi) or lower.) (b) When the A/C and blower switches are ON, check that there is no continuity between terminals 2 and 3. (When the pressure is 1,520 kPa (15.5 kgf/cm2, 220 psi) or higher.) If continuity is not as specified, replace the switch. 4. REMOVE MANIFOLD GAUGE SET 5. RECONNECT A/C HIGH–PRESSURE SWITCH CONNECTOR Solenoid Valve SOLENOID VALVE INSPECTION INSPECT SOLENOID VALVE Using an ohmmeter, measure the resistance between the terminals Resistance: 7.6 – 8.0Ω at 25°C (77°F) If the resistance is not as specified, replace the sole– noid valve. EG2–366 1MZ–FE ENGINE SERVICE SPECIFICATIONS SERVICE DATA Thermostat Radiator cap Radiator On–vehicle inspection for hydraulic– driven cooling motor Hydraulic motor ECT sensor TORQUE SPECIFICATIONS Part tightened RH Drain plug x Cylinder block LH Drain plug x Cylinder block Water pump x Cylinder block No.3 timing belt cover x Cylinder head No.2 idler pulley x Cylinder heads Camshaft pulley x Camshaft Camshaft pulley x Camshaft (For use with SST) Water inlet x Water inlet housing Water inlet pipe x LH cylinder head Hydraulic motor pressure hose x Water inlet Radiator oil cooler x Radiator lower tank Radiator pipe x Radiator lower tank Pressure hose x Hydraulic motor Radiator support bolt Hydraulic motor housing x Motor cover Hydraulic motor x Fan shroud Cooling fen x Hydraulic motor Hydraulic cooling fan x Radiator Oil cooler (for hydraulic cooling fan) x RadiAtor lower support – COOLING SYSTEM EG2–367 1MZ–FE ENGINE – LUBRICATION SYSTEM LUBRICATION SYSTEM DESCRIPTION A fully pressurized, fully filtered lubrication system has been adopted for this engine. OPERATION CAMSHAFT GEARS VALVE LIFTERS & STEMS CAMSHAFT GEARS VALVE LIFTERS & STEM CAMS PISTONS CAMS CAMSHAFT JOURNALS CAMSHAFT JOURNALS CYLINDER HEAD (FOR LEFT BANK) CYLINDER HEAD (FOR RIGHT BANK) CONNECTING RODS CRANKSHAFT MAIN OIL HOLE RELIEF VALVE OIL FILTER RELIEF VALVE OIL PUMP OIL STRAINER OIL PAN EG2–368 1MZ–FE ENGINE – LUBRICATION SYSTEM A pressure feeding lubrication system has been adopted to supply oil to the moving parts of this engine. The lubrication system consists of an oil pan, oil pump, oil filter and other external parts which supply oil to the moving parts in the engine block. The oil circuit is shown in the illustration at the top of the previous page. Oil from the oil pan is pumped up by the oil pump. After it passes through the oil filter, it is fed through the various oil holes in the crankshaft and cylinder block. After passing through the cylinder block and performing its lubricating function, the oil is returned by gravity to the oil pan. A dipstick on the center left side of the cylinder block is provided to check the oil level. OIL PUMP The oil pump pumps up oil from the oil pan and feeds it under pressure to the various parts of the engine. An oil strainer is mounted in front of the inlet to the oil pump to remove impurities. The oil pump itself is a trochoid type pump, inside of which there is a drive rotor and a driven rotor. When the drive rotor rotates, the driven rotor rotates in the same direction, and since the axis of the drive rotor shaft is different from the center of the driven rotor, the space between the two rotors changes as they rotate. Oil is drawn in when the space is wide and is discharged when the space in narrow. OIL PRESSURE REGULATOR (RELIEF VALVE) At high engine speeds, the engine oil supplied by the oil pump exceeds the capacity of the engine to utilize it. For that reason, the oil pressure regulator works to prevent an oversupply of oil. –During normal oil supply, a coil spring and valve keep the bypass closed, but when too much oil is being fed, the pressure become extremely high, overpowering the force of the spring and opening the valves. This allows the excess oil to flow through the relief valve and return to the oil pan. OIL FILTER The oil filter is a full flow type filter with a built–in paper filter element. Particles of metal from wear, airborne dirt, carbon and other impurities can get into the oil during use and could cause accelerated wear or seizing if allowed to circulate through the engine. The oil filter, integrated into the oil line, removes these impurities as the oil passes through it. The filter is mounted outside the engine to simplify replacement of the filter element. A relief valve is also included ahead of the filter element to relieve the high oil pressure in case the filter element becomes clogged with impurities. The relief valve opens when the oil pressure overpowers the force of the spring. Oil passing through the relief valve bypasses the oil filter and flows directly into the main oil hole in the engine. EG2–369 1MZ–FE ENGINE – LUBRICATION SYSTEM PREPARATION SST (SPECIAL SERVICE TOOLS) 09032–00100 Oil Pan Seal Cutter No.2 oil pan 09223–00010 Cover & Seal Replacer Crankshaft front oil seal 09226–07500 Oil Filter Wrench 09816–30010 Oil Pressure Switch Socket RECOMMENDED TOOLS 09200–00010 Engine Adjust Kit EQUIPMENT Oil pressure gauge Precision straight edge Oil pump Torque wrench LUBRICANT Item Engine oil Dry fill Drain and refill w/ Oil filter change w/o Oil filter change Capacity Classification 5.5 liters (5.8 US qts, 4.8 Imp. qts) API grade SG or SH, Energy–Conserving II or ILSAC multigrade and recommended viscosity oil with SAE 5W–30 being the preferred engine oil 4.7 liters (5.0 US qts, 4.1 Imp. qts) 4.5 liters (4.8 US qts, 4.0 Imp. qts) EG2–370 1MZ–FE ENGINE – LUBRICATION SYSTEM SSM (SPECIAL SERVICE MATERIALS) 08826–00080 Seal packing or equivalent Oil pump No.1 oil pan No.2 oil pan 08833–00080 Adhesive 1344, THREE BOND 1344, LOCTITE 242 or equivalent Oil pressure switch OIL PRESSURE CHECK 1. CHECK ENGINE OIL QUALITY Check the oil for deterioration, entry of water, dis– coloring or thinning. If the quality is visibly poor, replace the oil. Oil grade: API grade SG or SH, Energy – Conserving II or ILSAC multigrade engine oil. Recommended viscosi– ty is as shown in the illustration with SAE 5W–30 being the preferred engine oil. 2. CHECK ENGINE OIL LEVEL The oil level should be between the ”L” and ”F” marks on the dipstick. If low, check for leakage and add oil up to the ”F” mark. NOTICE: • Do not fill with engine oil above the ”F” mark. • Install the oil dipstick facing the direction shown in the illustration. 3. REMOVE OIL PRESSURE SWITCH, AND INSTALL OIL PRESSURE GAUGE (a) Using SST, remove the oil pressure switch. SST 09816 – 30010 EG2–371 1MZ–FE ENGINE – LUBRICATION SYSTEM (b) Install the oil pressure gauge. 4. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 5. CHECK OIL PRESSURE Oil pressure: At idle speed 29 kPa (0.3 kgf/cm2, 4.3 psi) or more At 3,000 rpm 294 – 539 kPa (3.0 – 5.5 kgf/cm2, 43 – 78 psi) 6. REMOVE OIL PRESSURE GAUGE AND REINSTALL OIL PRESSURE SWITCH (a) Remove the oil pressure gauge. (b) Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833–00080, THREE BOND 1344, LOCTITE 242 or equivalent (c) Using SST, reinstall the oil pressure switch. SST 09816–30010 Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) 7. START ENGINE AND CHECK FOR LEAKS EG2–372 1MZ–FE ENGINE – LUBRICATION SYSTEM OIL AND FILTER REPLACEMENT CAUTION: • Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addi– tion, used engine oil contains potentially harmful contaminants which may cause skin cancer. • Exercise caution in order to minimize the length and frequency of contact of your skin to used oil. Wear protective clothing end gloves. Wash your skin thor– oughly with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents. • In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal sites. 1. DRAIN ENGINE OIL (a) Remove the oil filler cap. (b) Remove the oil drain plug, and drain the oil into a container. 2. REPLACE OIL FILTER (a) Using SST, remove the oil filter. SST 09228–07500 (b) Check and clean the oil filter installation surface. EG2–373 1MZ–FE ENGINE – LUBRICATION SYSTEM (c) Apply clean engine oil to the gasket of a new oil filter. (d) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. (e) Using SST, tighten it an additional 3/4 turn. SST 09228–07500 3. REFILL WITH ENGINE OIL (a) Clean and install the oil drain plug with a new gasket. Torque: 37 N–m (375 kgf–cm, 27 ft–lbf) (b) Fill with fresh engine oil. Oil grade: API grade SG or SH, Energy – Conserving II or ILSAC multigrade and recommended viscosity oil, with SAE 5W–30 being the preferred engine oil. Capacity: Drain and refill w/ Oil filter change 4.7 liters (5.0 US qts, 4.1 Imp. qts) w/o Oil filter change 4.5 liters (4.8 US qts, 4.0 Imp. qts) Dry fill 5.5 liters (5.8 US qts, 4.8 Imp. qts) (c) Reinstall the oil filler cap. 4. START ENGINE AND CHECK FOR OIL LEAKS 5. RECHECK ENGINE OIL LEVEL EG2–374 1MZ–FE ENGINE – LUBRICATION SYSTEM OIL PUMP COMPONENTS FOR REMOVAL AND INSTALLATION EG2–375 1MZ–FE ENGINE – LUBRICATION SYSTEM EG2–376 1MZ–FE ENGINE – LUBRICATION SYSTEM EG2–377 1MZ–FE ENGINE – LUBRICATION SYSTEM OIL PUMP REMOVAL (See Components for Removal and Installation) HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned. 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the Ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable Is discon– nected from the battery. 2. DRAIN ENGINE OIL 3. REMOVE OIL DIPSTICK 4. REMOVE TIMING BELT (See step 2 to 20 on pages EG2–41 to 45) 5. REMOVE TIMING PULLEYS (See step 21 to 24 on pages EG2–45 to 47) 6. DISCONNECT ENGINE WIRE (a) Disconnect the crankshaft position sensor connector. (b) Disconnect the engine wire from the wire clamp. (c) Disconnect the generator connector. (d) Remove the nut and disconnect the generator wire. (e) Disconnect the engine wire from the 3 clamps. 7. REMOVE No.3 TIMING BELT COVER Remove the 6 bolts and belt cover. EG2–378 1MZ–FE ENGINE – LUBRICATION SYSTEM 8. REMOVE GENERATOR Remove the 2 bolts and generator. 9. REMOVE CRANKSHAFT POSITION SENSOR Remove the bolt and position sensor. 10. REMOVE OIL HOLE COVER PLATE Remove the 4 bolts and cover plate. 11. REMOVE A/C COMPRESSOR WITHOUT DISCONNECTING HOSES (a) Disconnect the A/C compressor connector. (b) Remove the drive belt. (c) Remove the 5 bolts, 2 nuts and drive belt adjusting bar bracket, and disconnect the A/C compressor. (d) Move the compressor aside and suspend it. 12. REMOVE A/C COMPRESSOR HOUSING BRACKET Remove the 3 bolts and A/C compressor housing bracket. EG2–379 1MZ–FE ENGINE – LUBRICATION SYSTEM 13. REMOVE FRONT EXHAUST PIPE (a) Remove the 2 bolts and exhaust pipe clamp. (b) Remove the 2 bolts, and disconnect the bracket. (c) Remove the 2 bolts and 2 nuts holding the front exhaust pipe to the three–way catalytic converter. (d) Remove the 4 nuts holding the front exhaust pipe to the exhaust manifolds. (e) Remove the front exhaust pipe and 3 gaskets. 14. REMOVE FRONT EXHAUST PIPE STAY Remove the 2 bolts and pipe stay. 15. REMOVE FLYWHEEL HOUSING UNDERCOVER Remove the 2 bolts and undercover. 16. REMOVE BOLTS HOLDING NO.1 OIL PAN TO TRANSAXLE Remove the 2 bolts. EG2–380 1MZ–FE ENGINE – LUBRICATION SYSTEM 17. REMOVE NO.2 OIL PAN (a) Remove the 10 bolts and 2 nuts. (b) Insert the blade of SST between the No. 1 and No.2 oil pans, and cut off applied sealer and remove the No. 1 oil pan. SST 09032 – 00100 NOTICE: • Be careful not to the damage the No.2 oil pan con– tact surface of the No.1 oil pan. • Be careful not to damage the No..2 oil pan flange. 18. REMOVE OIL STRAINER Remove the bolt, 2 nuts, oil strainer and gasket. 19. REMOVE NO.1 OIL PAN (a) Remove the 17 bolts. EG2–381 1MZ–FE ENGINE – LUBRICATION SYSTEM (b) Using a screwdriver, remove the No. 1 oil pan by prying the portions between the cylinder block and No.1 oil pan. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and No.1 oil pan. 20. REMOVE OIL PAN BAFFLE PLATE Remove the 6 bolts and baffle plate. 21. REMOVE OIL PUMP (a) Remove the 9 bolts. (b) Remove the oil pump by prying a screwdriver between the oil pump and main bearing cap. (c) Remove the 0–ring. EG2–382 1MZ–FE ENGINE – LUBRICATION SYSTEM COMPONENTS FOR DISASSEMBLY AND ASSEMBLY OIL PUMP DISASSEMBLY 1. REMOVE RELIEF VALVE Remove the plug, gasket, spring and relief valve. 2. REMOVE DRIVE AND DRIVEN ROTORS Remove the 9 screws, pump body cover, drive and driven rotors. EG2–383 1MZ–FE ENGINE – LUBRICATION SYSTEM OIL PUMP INSPECTION 1. INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it does not, replace the relief valve. If necessary, replace the oil pump assembly. 2. INSPECT DRIVE AND DRIVEN ROTORS A. Place drive and driven rotors into oil pump body Place the drive and driven rotors into the oil pump body with the mark facing upward. B. Inspect rotor side clearance Using a feeler gauge and precision straight edge, mea– sure the clearance between the rotors and precision straight edge. Standard side clearance: 0.030 – 0.090 mm (0.0012 – 0.0035 in.) Maximum side clearance: 0.15 mm (0.0059 in.) If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. C. Inspect rotor tip clearance Using a feeler gauge, measure the clearance between the drive and driven rotor tips. Standard tip clearance: 0.110 – 0.240 mm (0.0043 – 0.0094 In.) Maximum tip clearance: 0.35 mm (0.0138 in.) If the tip clearance is greater than maximum, replace the rotors as a set. EG2–384 1MZ–FE ENGINE – LUBRICATION SYSTEM D. Inspect rotor body clearance Using a feeler gauge, measure the clearance between the driven rotor and body. Standard body clearance: 0.100 – 0.175 mm (0.0039 – 0.0069 In.) Maximum body clearance: 0.30 mm (0.0118 in.) If the body clearance is greater than maximum, re– place the rotors as a set. If necessary, replace the oil pump assembly. CRANKSHAFT FRONT OIL SEAL REPLACEMENT HINT: There are 2 methods (A and B) to replace the oil seal which are as follows: REPLACE CRANKSHAFT FRONT OIL SEAL A. If oil pump is removed from cylinder block: (a) Using a screwdriver, pry out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge. SST 09223 – 00010 (c) Apply MP grease to the oil seal lip. B. If oil pump is installed to the cylinder block: (a) Using a knife, cut off the oil seal lip. (b) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. EG2–385 1MZ–FE ENGINE – LUBRICATION SYSTEM (c) Apply MP grease to a new oil seal lip. (d) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump body edge. SST 09223 – 00010 OIL PUMP ASSEMBLY (See Components for Disassembly and Assembly) 1. INSTALL DRIVE AND DRIVEN ROTORS (a) Place the drive and driven rotors into pump body with the marks facing the pump body cover side. (b) Install the pump body cover with the 9 screws. 2. INSTALL RELIEF VALVE (a) Insert the relief valve and spring into the pump body hole. (b) Install the plug with a new gasket. Torque: 36.8 N–m (375 kgf–cm, 37 ft–lbf) EG2–386 1MZ–FE ENGINE – FE ENGINE – LUBRICATION SYSTEM OIL PUMP INSTALLATION (See Components for Removal and Installation) 1. INSTALL OIL PUMP (a) Remove any old packing (FIPG) material and be care– ful not to drop any oil on the contact surfaces of the oil pump and cylinder block. • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. • Thoroughly clean all components to remove all the loose material. • Using a non–residue solvent, clean both sealing surfaces. (b) Apply seal packing to the oil pump as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent • Install a nozzle that has been cut to a 2–3 mm (0.08–0.12 in.) opening. HINT: Avoid applying an excessive amount to the surface. • Parts must be assembled within 3 minutes of application. Otherwise the material must be re– moved and reapplied. • Immediately remove nozzle from the tube and reinstall cap. (c) Place a new 0 – ring in position on the cylinder block. (d) Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft. EG2–387 1MZ–FE ENGINE – LUBRICATION SYSTEM (e) Install the oil pump with the 9 bolts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) for 10 mm head bolt 19.5 N–m (200 kgf–cm, 14 ft–lbf) for 12 mm head bolt 2. INSTALL OIL PAN BAFFLE PLATE Install the baffle plate with the 6 bolts. Torque: 8 N–m (80 kgf–cm, 69 in.–Ibf) 3. INSTALL NO.1 OIL PAN (a) Remove any old packing (FIPG) material and be care– f uI not to drop any oil on the contact surfaces of the oil pan, oil pump and cylinder block. • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. • Thoroughly clean all components to remove all the loose material. • Using a non–residue solvent, clean both sealing surfaces. (b) Apply seal packing to the oil pan as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent Region “X” is at the outer side of the bolt hole. Region “Y” Is at the inner side of the bolt hole. • Install a nozzle that has been cut to a 4–5 mm (0.16–0.20 in.) opening. HINT: Avoid applying an excessive amount to the surface. • Parts must be assembled within 3 minutes of application. Otherwise the material must be re– moved and reapplied. • Immediately remove nozzle from the tube and reinstall cap. EG2–388 1MZ–FE ENGINE – LUBRICATION SYSTEM (c) Install the oil pan with the 17 bolts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) for 10 mm head bolt 19.5 N–m (200 kgf–cm. 14 ft–lbf) for 12 mm head bolt 4. INSTALL OIL STRAINER Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) 5. INSTALL NO.2 OIL PAN (a) Remove any old packing (FIPG) material and be care. ful not to drop any oil on the contact surface of the No. 1 and No.2 oil pans. • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. • Thoroughly clean all components to remove al the loose material. • Using a non–residue solvent, clean both sealing surfaces. NOTICE: Do not use a solvent which will affect the paint ed surfaces. (b) Apply seal packing to the No.2 oil pan as shown in the illustration. Seal packing: Part No. 088218–00080 or equivalent • Install a nozzle that has been cut to a 4–5 mm (0.16 – 0.20 in.) opening. HINT: Avoid –applying an excessive amount to the surface. • Parts must be assembled within 3 minutes an application. Otherwise the material must be re– moved and reapplied. • Immediately remove nozzle from the tube and reinstall cap. EG2–389 1MZ–FE ENGINE – LUBRICATION SYSTEM (c) Install the No.2 oil pan with the 10 bolts and 2 nuts. Torque: 8 N–m (80 kgf–cm, 69 in.–lbf) 6. INSTALL BOLTS HOLDING NO.1 OIL PAN TO TRANSAXLE Install the 2 bolts. Torque: 37 N–m (380 kgf–cm, 27 ft–lbf) 7. INSTALL FLYWHEEL HOUSING UNDERCOVER Install the undercover with the 2 bolts. Torque: 7.8 N–m (80 kgf–cm, 69 in.–lbf) 8. INSTALL FRONT EXHAUST PIPE STAY Install the pipe stay with the 2 bolts. Torque: 21 N–m (210 kgf–cm, 15 ft–lbf) 9. INSTALL FRONT EXHAUST PIPE (a) Temporarily install 3 new gaskets and the front ex– haust pipe with the 2 bolts and6 nuts. (b) Tighten the 4 nuts holding the exhaust manifolds to the front exhaust pipe. Torque: 62 N–m (630 kgf–cm, 46 ft–lbf) (c) Tighten the 2 bolts and 2 nuts holding the three–way catalytic converter to the front exhaust pipe. Torque: 56 N–m (570 kgf–cm, 41 ft–lbf) (d) Connect the bracket with the 2 bolts. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) EG2–390 1MZ–FE ENGINE – LUBRICATION SYSTEM (e) Connect the front exhaust pipe clamp with the 2 bolts. Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) 10. INSTALL A/C COMPRESSOR HOUSING BRACKET Install the housing bracket with the 3 bolts. Torque: 26 N–m (250 kgf–cm, 18 ft–lbf) 11. INSTALL A/C COMPRESSOR (a) Install the A/C compressor and drive belt adjusting bar bracket with the 5 bolts. Torque: 25 N–m (250 kgf–cm, 18 ft–lbf) 12. INSTALL OIL HOLE COVER PLATE Install a new gasket and the hole cover plate (J mark facing outward) with the 4 bolts. Torque: 8 N–m (80 kgf–cm, 69 in.–Ibf) 13. INSTALL CRANKSHAFT POSITION SENSOR Install the position sensor with the bolt. Torque: 8 N–m (80 kgf–cm, 89 in.–lbf) EG2–391 1MZ–FE ENGINE – LUBRICATION SYSTEM 14. INSTALL GENERATOR Install the generator with the 2 bolts. Do not tighten the bolts yet. 15. INSTALL NO.3 TIMING BELT COVER (a) Check that the timing belt cover gaskets have no cracks or peeling, etc. If the gaskets do have cracks or peeling etc., replace them using the following steps. (1) Using a screwdriver and gasket scraper, remove all the old gasket material. (2) Thoroughly clean all components to remove all the loose material. (3) Remove the backing paper from a new gasket and install the gasket evenly to the part of the belt cover shaded black in the illustration. NOTICE: When joining gaskets, do not leave a gap be– tween them. Cut off any excess gasket. (4) After installing the gasket, press down on it so that the adhesive firmly sticks to the belt cover. (b) Install new gaskets to the No.3 belt cover. (c) Install the belt cover with the 6 bolts. Torque: 8.5 N–m (85 kgf–cm. 74 in.–lbf) 16. CONNECT ENGINE WIRE (a) Connect the generator connector. (b) Connect the generator wire with the nut. (c) Connect the engine wire with the 3 clamps. EG2–392 1MZ–FE ENGINE – LUBRICATION SYSTEM (d) Connect the crankshaft position sensor connector. (e) Connect the engine wire with the wire clamp. 17. INSTALL TIMING PULLEYS (See steps 1 to 5 on pages EG2–49, 50) 18. INSTALL TIMING BELT (See steps6 to 27 on pages EG2–51 to 66) 19. FILL ENGINE WITH OIL Capacity: Drain and refill w/ Oil filter change 4.7 liters (5.0 US qts, 4.1 Imp. qts) w/o Oil filter change 4.5 liters (4.8 US qts, 4.0 Imp. qts) 20. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 21. START ENGINE AND CHECK FOR LEAKS 22. RECHECK ENGINE ENGINE OIL LEVEL EG2–393 1MZ–FE ENGINE – SERVICE SPECIFICATIONS SERVICE DATA Oil pressure At idle speed (normal operating temperature) At 3,000 rpm (normal operating temperature) Oil pump Side clearance STD Maximum Body clearance STD Maximum Tip clearance STD Maximum TORQUE SPECIFICATIONS Pert tightened Oil pressure switch x Cylinder block No.2 oil pan x Drain plug Oil pump x Plug (for relief valve) Oil pump x Cylinder block (10 mm head bolt) Oil pump x Cylinder block (12 mm head bolt) Oil pan baffle plate x No.1 oil pan No.1 idler pulley x Oil pump No. 1 oil pan x Cylinder block No. 1 oil pan x Oil pump No.1 oil pan x Rear oil seal retainer Oil strainer x Main bearing cap Oil strainer x Oil pump No.2 oil pan x No. 1 oil pan Flywheel housing under cover x Transaxle Exhaust pipe stay x No.1 oil pan Exhaust pipe clamp x Exhaust pipe stay A/C compressor housing bracket x Cylinder block A/C compressor x A/C compressor housing bracket Oil hole cover plate x No.2 oil pan No.1 oil pan x Transaxle case Front exhaust pipe x Exhaust manifold Front exhaust pipe x Converter Crankshaft position sensor x Oil pump No.3 timing belt cover x Cylinder head LUBRICATION SYSTEM EG2–394 1MZ–FE ENGINE – 1MZ–FE ENGINE TROUBLESHOOTING EG2–395 1MZ–FE ENGINE – EG2–396 1MZ–FE ENGINE – HOW TO PROCEED WITH TROUBLESHOOTING HOW TO PROCEED WITH TROUBLESHOOTING The Engine Control System broadly consists of the sensors, ECM and actuators. The ECM receives signals from various sensors, judges the operating conditions and determines the optimum injection duration, timing, ignition timing and idle speed. In general, the Engine Control System is considered to be a very intricate system to troubleshoot. But, the fact is that if you inspect each circuit in order following the procedures in this manual, troubleshooting of this system is not complex. When troubleshooting OBDll vehicles, use an OBDII scan tool complying with SAE J1978 or TOYOTA hand–held –tester to confirm the diagnostic trouble codes, freezed frame data and engine data. This will enable you to determine the system causing the problem. This section explains the best method of troubleshooting and how to carry out the necessary repairs. (1) CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the customer in detail about the problem. (2) CONNECT OBDII SCAN TOOL OR TOYOTA HAND–HELD TESTER TO DLC 3 Connect the OBDII scan tool complying with SAE J1978 or TOYOTA hand–held tester to the vehicle’s data link connector 3. NOTICE: For OBDII scan tool or TOYOTA hand–held tester operating instructions, see the in– struction booklet accompanying the scan tool or tester. If your display shows ”UNABLE” TO CONNECT TO VEHICLE” when you have connected the scan tool/TOYOTA hand–held tester cable to DLC 3, turn the ignition switch ON and operate the scan tool/TOYOTA hand–held tester, inspect DLC (See page EG2–401) (3) CHECK DIAGNOSTIC TROUBLE CODE AND FREEZED FRAME DATA (PRECHECK) First check the diagnostic trouble codes. If a code is output, make a note of it. Also check and note the freezed frame data. HINT: Output of the malfunction code indicates a circuit malfunction. However, it does not indicate whether the malfunction is still occurring or occurred in the past and returned to normal. To determine this, first confirm the problem symptoms in (7) and then recheck the diagnostic trouble code in (9). If troubleshooting started based only on the malfunction code in the diagnostic trouble code check in (3) , it could result in a misdiagnosis and troubleshooting of circuits which are normal, making it more difficult to locate the cause of the problem. (4) CLEAR DIAGNOSTIC TROUBLE CODE AND FREEZED FRAME DATA Use the OBDII scan tool or TOYOTA hand–held tester to erase the diagnostic trouble codes and freezed frame data. NOTICE: For OBDII scan tool or TOYOTA hand–held tester operating instructions, see the in– struction booklet accompanying the scan tool. (5) VISUAL INSPECTION EG2–397 1MZ–FE ENGINE – HOW TO PROCEED WITH TROUBLESHOOTING (6) SETTING CHECK MODE DIAGNOSIS (7) PROBLEM SYMPTOM CONFIRMATION If the engine does not start, first carry out steps (10) and (12) while referring to the diagnostic trouble codes confirmed in step (4) . (8) SYMPTOM SIMULATION To find the trouble more quickly, set the diagnosis check to check mode and confirm the problem symptoms with the higher sensing ability of the ECM. If the trouble does not reappear, use the symptom simulation method to make sure the trouble can be reproduced. (9) DIAGNOSTIC TROUBLE CODE CHECK IN CHECK MODE Check the diagnostic trouble code in check mode. If a malfunction code is output, proceed to step (11) of the Diagnostic Trouble Code Chart. If a malfunction code is not output, proceed to step (10) Basic Inspection. (10) BASIC INSPECTION Carry out basic inspection such as the spark check and fuel pressure check, etc. (11) DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed, inspect the circuit indicated by the chart for each code. (12) MATRIX CHART OF PROBLEM SYMPTOMS If a diagnostic trouble code is not displayed in the diagnosis in check mode, troubleshoot according to the inspection order in the Matrix Chart of Problem Symptoms. (13) CIRCUIT INSPECTION Determine if the malfunction is in the sensor, actuator, wire harness, connector or the ECM. (14) PARTS INSPECTION When the Matrix Chart of Problem Symptoms instructs you to check the parts, refer to the parts inspection section in this manual. (15) CHECK FOR INTERMITTENT PROBLEMS By checking for intermittent problems, you can isolate the place where momentary interruptions or momentary shorts are occurring due to poor contacts. (16) ADJUSTMENT, REPAIR After you locate the cause of the problem, follow the inspection and replacement procedures in this manual and adjust or repair as necessary. (17) CONFIRMATION TEST After completing adjustment or repairs, confirm not only that the malfunction is eliminated, but also test drive the vehicle, to make sure the entire Engine Control System is operating normally. EG2–398 1MZ–FE ENGINE – HOW TO PROCEED WITH TROUBLESHOOTING Titles inside are titles of pages in this manual, with the page number indi– cated in the bottom portion. See the indicated pages for detailed explanations. Vehicle Brought to workshop Customer Problem Analysis P EG2–399 Connect the OBDII scan tool or Toyota hand–held tester to DLC3. P. EG2–402 If the display indicates a communication fault in the tool, inspect DLC3. See page EG2–401 Check Diagnostic Trouble Code and Freezed Frame Data Check Record or print DTC and Freezed Frarne Data. P. EG2–402 Clear Diagnostic Trouble Code and Freezed Frame Data P. EG2–403 Visual Inspection Setting the Check Mode Diagnosis P EG2–403 Problem Symptom Confirmation if the engine does not start, perform steps 10 and 12 first Malfunction does not occur. Symptom Simulation P IN–24 Malfunction occurs. Diagnostic Trouble Code Check P EG2–403 Normal Basic Inspection EG2–420 Malfunction code. Diagnostic Trouble Code Chart P. EG2–404 Matrix Chart of Problem Symptoms P EG2–435 Circuit Inspection P EG2–444 Parts Inspection ldentification of Problem Adjustment, Repair. Confirmation Test END Check for Intermittent Problems P EG2–417 EG2–399 1MZ–FE ENGINE – CUSTOMER PROBLEM ANALYSIS CHECK SHEET CUSTOMER PROBLEM ANALYSIS CHECK SHEET ENGINE CONTROL System Check Sheet Inspector’s Name EG2–400 1MZ–FE ENGINE – DIAGNOSIS SYSTEM DIAGNOSIS SYSTEM DESCRIPTION When troubleshooting OBDII vehicles, the only difference from the usual troubleshooting procedure is that you connect to the vehicle the OBDll scan tool complying with SAE J1978 or TOYOTA hand–held tester, and read off various data output from the vehicle’s ECM. OBDll regulations require that the vehicle’s on–board com– puter lights up the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in the computer itself or in drive system components which af– fect vehicle emissions. In addition to the MIL lighting up when a malfunction is detected, the applicable diagnostic trouble codes prescribed by SAE J2012 are recorded in the ECM memory. (See page EG2–404) If the malfunction does not reoccur in 3 trips, the MIL goes off but the diagnostic trouble codes remain recorded in the ECM memory. To check the diagnostic trouble codes, connect the OBDII scan tool or TOYOTA hand–held tester to Data Link Connec– tor 3 on the vehicle. The OBDII scan tool or TOYOTA hand– held tester also enables you to erase the diagnostic trouble codes and check freezed frame data and various forms of engine data. (For operating instructions, see the OBDII scan tool’s instruction book.) Diagnostic trouble codes include SAE controlled codes and Manufacturer controlled codes. SAE controlled codes must be set as prescribed by the SAE, while Manufacturer controlled codes can be set freely by the manufacturer within the prescribed limits. (See diagnostic trouble code chart on page EG2–404) The diagnosis system operates in normal mode during normal vehicle use. It also has a check mode for technicians to simu– late malfunction symptoms and troubleshoot. Most diagnos– tic trouble codes use 2 trip detection logic*to prevent erro– neous detection and ensure thorough malfunction detection. By switching the ECM to check mode when troubleshooting, the technician can cause the MIL to light up for a malfunction that is only detected once or momentarily. (TOYOTA hand– held tester only) (See page EG2–403) *2 trip detection logic When a logic malfunction is first detected, the malfunction is temporarily stored in the ECM memory. If the same malfunc– tion is detected again during the second drive test, this sec– ond detection causes the MIL to light up. The 2 trip repeats the same mode a 2nd time. (However, the IG switch must be turned OFF between the 1 st trip and 2nd trip). EG2–401 1MZ–FE ENGINE – DIAGNOSIS SYSTEM Freeze frame data: Freeze frame data records the engine condition when a misfire (DTC P0300 – P0306) or fuel trim malfunction (DTC P0171, P0172), or other malfunction (first malfunc– tion only), is detected. Because freeze frame data records the engine conditions (fuel system, calculator load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when the mal– function 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. Priorities for Troubleshooting: If troubleshooting priorities for multiple diagnostic codes are given in the applicable diagnostic chart, these should be followed. If no instructions are given, troubleshoot diagnostic trouble codes according to the following priorities. (1) Diagnostic trouble codes other than fuel trim malfunc– tion (DTC P0171, P0172) and EGR (DTC P0401, P0402) and misfire (DTC P0300 – P0306). (2) Fuel trim malfunction (DTC P0171, P0172) and EGR (DTC P0401, P0402) (3) Misfire (DTC P0300 – P0306). DATA LINK CONNECTOR 3 INSPECTION The vehicle’s ECM uses V.P.W. (Variable Pulse Width) for communication to comply with SAE J1850. The terminal ar– rangement of DLC 3 complies with SAE J1962 and matches the V. P.W. format. Terminal No. Connection Bus (+) Line Voltage or Resistance Condition Pulse generation During transmission Chassis Ground ↔ Body Ground 1 0 or less Always Signal Ground ↔ Body Ground 1 0 or less Always Battery Positive ↔ Body Ground 9 – 14 V Always HINT: If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of the OBDII scan tool or TOYOTA hand–held tester to DLC 3, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or tool side. 1) If communication is normal when the tool is connected to another vehicle, inspect DLC 3 on the original vehicle. 2) If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service Department listed in the tool’s instruction manual. EG2–402 1MZ–FE ENGINE – DIAGNOSIS SYSTEM Diagnosis Inspection (Normal Mode) MALFUNCTION INDICATOR LAMP CHECK 1. The malfunction indicator lamp comes on when the igni– tion switch is turned ON and the engine is not running. HINT: If the malfunction indicator lamp does not light up, troubleshoot the combination meter. (See page BE–64). 2. When the engine is started, the malfunction indicator lamp should go off. If the lamp remains on, the diagnosis system has detected a malfunction or abnormality in the system. DIAGNOSTIC TROUBLE CODE CHECK NOTICE (TOYOTA hand–held tester only): When the diag– nosis system is switched from normal mode to check mode, it erases all diagnostic trouble codes and freezed frame data recorded in normal mode. So before switching modes, always check the diagnostic trouble codes and freezed frame data, and note them down. 1. Prepare the OBDII scan tool (complying with SAE J1978) or TOYOTA hand–held tester. 2. Connect the OBDll scan tool or TOYOTA hand–held tester to data link connector 3 in the fuse box at the lower left of the instrument panel. 3. Turn the ignition switch ON and turn the OBDII scan tool or TOYOTA hand–held tester switch ON. 4. Use the OBDII scan tool or TOYOTA hand–held tester to check the diagnostic trouble codes and freezed frame data, note them down. (For operating instructions, see the OBDll scan tool’s instruction book.) 5. See page EG2–404 to confirm the details of the diagnostic trouble codes. NOTICE: When simulating symptoms with an OBDll scan tool (excluding TOYOTA hand–held tester) to check the di– agnostic trouble codes, use normal mode. For codes on the diagnostic trouble code chart subject to ”2 trip detection logic”, turn the ignition switch OFF after the symptom is simulated the first time. Then repeat the simulation process again. When the problem has been simulated twice, the MIL lights up and the diagnostic trouble codes are recorded in the ECM . Diagnosis Inspection (Check Mode) TOYOTA HAND–HELD TESTER only Compared to the normal mode, the check mode has an in– creased sensitivity to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check mode. EG2–403 1MZ–FE ENGINE – DIAGNOSIS SYSTEM DIAGNOSTIC TROUBLE CODE CHECK 1. Initial conditions. (a) Battery positive voltage 11 V or more. (b) Throttle valve fully closed. (c) Transmission in park or neutral position. (d) Air conditioning switched OFF. 2. Turn ignition switch OFF. 3. Prepare the TOYOTA hand–held tester. 4. Connect the TOYOTA hand–held tester to data link con– nector 3 in the fuse box at the lower left of the instrument panel. 5. Turn the ignition switch ON and switch the TOYOTA hand–held tester ON. 6. Switch the TOYOTA hand–held tester normal mode to check mode. (Check that the MIL flashes.) 7. Start the engine. (The MIL goes out after the engine start.) 8. Simulate the conditions of the malfunction described by the customer. NOTICE: Leave the ignition switch ON until you have checked the diagnostic trouble codes, etc. 9. After simulating the malfunction conditions, use the TOYOTA hand–held tester diagnosis selector to check the diagnostic trouble codes and freezed frame data, etc. HINT: Take care not to turn the ignition switch OFF. Turning the ignition switch OFF switches the diagnosis system from check mode to normal mode, so all diagnos– tic codes, etc. are erased. 10. After checking the diagnostic trouble code, inspect the applicable circuit. DIAGNOSTIC TROUBLE CODE CLEARANCE The following actions will erase the diagnostic trouble codes and freezed frame data. 1. Operating the OBDII scan tool (complying with SAE J1978) or TOYOTA hand–held tester to erase the codes. (See the OBDII scan tool’s instruction book for operat– ing instructions.) 2. Disconnecting the battery terminals or EFI fuse. NOTICE: If the TOYOTA hand–held tester switches the ECM from normal mode to check mode or vice–versa, or if the ignition switch is turned from ON to ACC or OFF during check mode, the diagnostic trouble codes and freezed frame data will be erased. EG2–404 1MZ–FE ENGINE – DIAGNOSTIC TROUBLE CODE CHART DIAGNOSTIC TROUBLE CODE CHART (SAE Controlled) HINT: Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors. DTC No. Detection Item Diagnostic Trouble Code Detecting Condition P0100 Mass Air Flow Circuit Malfunction Open or short in mass air flow meter circuit with engine speed 4,000 rpm or less. P0101 Mass Air Flow Circuit Range/ Performance Problem Conditions a) and b) continue with engine speed 900 rpm or less. (2 trip detection logic) a) Closed throttle position switch: ON b) Mass air flow meter output ) 2.2 V P0110 Intake Air Temp. Circuit Malfunction Open or short in intake air temp. sensor circuit. P0115 Engine Coolant Temp. Circuit Malfunction Open or short in engine coolant temp. sensor circuit. P0116 Engine Coolant Temp. Circuit Range/ Performance Problem 20 min. or more after starting engine, engine coolant temp. sensor value is 30
C (86
F) or less. (2 trip detection logic) P0120 Throttle Position Circuit Malfunction Condition a) or b) continues. a) VTA
( 0.1 V, and closed throttle position switch is OFF. b) VTA )  4.9 V P0121 Throttle Position Circuit Range/ Performance Problem When closed throttle position switch is ON, condition a) continues. (2 trip detection logic) a ) VTA )  2.0 V P0125 Insufficient Coolant Temp. for Closed Loop Fuel Control After the engine is warmed up, heated oxygen sensor output does not indicate RICH even once when conditions a) and b) continue for at least 2 minutes. a) Engine speed: 1,500 rpm or more b) Vehicle speed: 40 km/h (25 mph) or more P01 30 Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 1) Voltage output of heated oxygen sensor remains at 0.4 V or more, or 0.55 V or less, during idling after the engine is warmed up. (2 trip detection logic) P0133 Heated Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 1) Response time for the heated oxygen sensor’s voltage output to change from rich to lean, or from lean to rich, is 1 sec. or more during idling after the engine is warmed up. (2 trip detection logic) EG2–405 1MZ–FE ENGINE – DIAGNOSTIC TROUBLE CODE CHART If a malfunction code is displayed during the diagnostic trouble code check in check mode, check the circuit for that code listed in the table below (Proceed to the page given for that circuit). Trouble Area MIL Memory See Page • • • Open or short in mass air flow meter circuit. Mass air flow meter ECM EG2–444 • Mass air flow meter EG2–450 • • • Open or short in intake air temp. sensor circuit. Intake air temp. sensor ECM • • • Open or short in engine coolant temp. sensor circuit. Engine coolant temp. sensor ECM EG2–457 • • Engine coolant temp. sensor Coolant system EG2–462 • • • Open or short in throttle position sensor circuit. Throttle position sensor. ECM EG2–463 EG2–451 • Throttle position sensor EG2–472 • • Open or short in heated oxygen sensor circuit. Heated oxygen sensor. EG2–473 • • Heated oxygen sensor Fuel trim malfunction EG2–476 • Heated oxygen sensor EG2–480 EG2–406 1MZ–FE ENGINE – DIAGNOSTIC TROUBLE CODE CHART DIAGNOSTIC TROUBLE CODE CHART (Cont’d) DTC No. P0135 Detection Item Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1) Diagnostic Trouble Code Detecting Condition When the heater operates, heater current exceeds 2 A or voltage drop for the heater circuit exceeds 5 V. (2 trip detection logic) Heater current of 0.25 A or less when the heater operates. (2 trip detection logic) P0136 Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) Voltage output of the heated oxygen sensor (bank1 sensor 2) remains at 0.4 V or more or 0.5 V or less when the vehicle is driven at 50 km/h (31 mph) or more after the engine is warmed up. (2 trip detection logic) P0141 Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 2) Same as DTC No. P01 35. P0150 Heated Oxygen Sensor Circuit Malfunction (Bank 2 Sensor 1) Same as DTC No. P01 30. P0153 Heated Oxygen Sensor Circuit Slow Response (Bank 2 Sensor 1) Same as DTC No. P01 33. P0155 Heated Oxygen Sensor Heater Circuit Malfunction (Bank 2 Sensor 1) Same as DTC No. P01 35. P0171 System too Lean (Fuel Trim) When the air fuel ratio feedback is stable after engine warming up, the fuel trim is considerably in error on the RICH side. (2 trip detection logic) P0172 System too Rich (Fuel Trim) When the air fuel ratio feedback is stable after engine warming up, the fuel trim is considerably in error on the LEAN side. (2 trip detection logic) P0201 P0202 P0203 P0204 P0205 P0206 Injector Circuit Malfunction – Cylinder 1 – Cylinder 2 – Cylinder 3 – Cylinder 4 – Cylinder 5 – Cylinder 6 A specified cylinder misfire continuously. (2 trip detection logic) EG2–407 1MZ–FE ENGINE Trouble Area – DIAGNOSTIC TROUBLE CODE CHART MIL Memory See Page • • • Open or short in heater circuit of heated oxygen sensor. Heated oxygen sensor heater ECM EG2–481 • Heated oxygen sensor EG2–484 • Same as DTC No. P01 35. EG2–481 • Same as DTC No. P01 30. EG2–476 • Same as DTC No. P01 33. EG2–480 • Same as DTC No. P01 35. EG2–481 • • • • • • Air intake (hose loose) Fuel line pressure Injector blockage Heated oxygen sensor malfunction Mass air flow meter Engine coolant temp. sensor EG2–486 • • • • • Fuel line pressure Injector leak, blockage Heated oxygen sensor malfunction Mass air flow meter Engine coolant temp. sensor EG2–486 • • • • • Open or short in injector circuit Injector blockage, seized Ignition system Valve clearance not to specification Compression pressure EG2–491 EG2–408 1MZ–FE ENGINE – DIAGNOSTIC TROUBLE CODE CHART DIAGNOSTIC TROUBLE CODE CHART (Cont’d) DTC No. P0300 P0301 P0302 P0303 P0304 P0305 P0306 Detection Item Random Misfire Detected Misfire Detected – Cylinder 1 – Cylinder 2 Diagnostic Trouble Code Detecting Condition Misfiring of multiple cylinders is detected during the same 200 or 1,000 revolutions. For each 200 revolutions of the engine, misfiring is detected which can cause catalyst overheating. (This causes MIL to blink.) – Cylinder 3 – Cylinder 4 – Cylinder 5 – Cylinder 6 For each 1,000 revolutions of the engine, misfiring is detected which causes emissions deterioration. (2 trip detection logic) P0325 Knock Sensor 1 Circuit Malfunction No knock sensor 1 signal to ECM with engine speed 2,000 rpm or more. P0330 Knock Sensor 2 Circuit Malfunction No knock sensor 2 signal to ECM with engine speed 2,000 rpm or more. P0335 Crankshaft Position Sensor Circuit Malfunction No crankshaft position sensor signal to ECM during cranking. (2 trip detection logic) No crankshaft position sensor signal to ECM during engine running. P0336 Crankshaft Position Sensor Circuit Range/ Performance P0340 Camshaft Position Sensor Circuit Malfunction Deviation in crankshaft position sensor signal and camshaft position sensor signal. (2 trip detection logic) No camshaft position sensor signal to ECM during cranking. (2 trip detection logic) No camshaft position sensor signal to ECM during engine running. P0401 Exhaust Gas Recirculation Flow Insufficient Detected After the engine is warmed up and run at 80 km/h (50 mph) for 3 to 5 minutes, the EGR gas temperature sensor value does not exceed 40
C (104
F) above the ambient air temperature, (2 trip detection logic) EG2–409 1MZ–FE ENGINE Trouble Area – DIAGNOSTIC TROUBLE CODE CHART MIL Memory See Page • • • • • • • • • Ignition system Injector Fuel line pressure EG R Compression pressure Valve clearance not to specification Valve timing Mass air flow meter Engine coolant temp. sensor EG2–493 • • • Open or short in knock sensor 1 circuit. Knock sensor 1 (looseness) ECM EG2–499 • • • Open or short in knock sensor 2 circuit. Knock sensor 2 (looseness) ECM EG2–499 • • • • Open or short in crankshaft position sensor circuit. Crankshaft position sensor Starter ECM EG2–503 • EG2–507 • Mechanical system malfunction (skipping teeth of timing belt, belt stretched) ECM • • • • Open or short in camshaft position sensor circuit. Camshaft position sensor Starter ECM EG2–508 • • • • • EGR valve stuck closed Short in EGR VSV circuit Open in EGR gas temp. sensor circuit EGR hose disconnected ECM EG2–512 EG2–410 1MZ–FE ENGINE – DIAGNOSTIC TROUBLE CODE CHART DIAGNOSTIC TROUBLE CODE CHART (Cont’d) DTC No. P0402 Detection Item Exhaust Gas Recirculation Flow Excessive Detected Diagnostic Trouble Code Detecting Condition EG R gas temp. sensor value is high during EGR cut–off when engine is cold (Race engine at about 4,000 rpm without load so that vacuum is applied to port E). (2 trip detection logic) EG R valve is always open. (2 trip detection logic) P0420 Catalyst System Efficiency Below Threshold After the engine is warmed up and the vehicle driven for 5 min. at 32 – 80 km/h (20 – 50 mph), the waveforms of the heated oxygen sensors, bank 1, 2 sensor 1 and bank 1 sensor 2 have the same amplitude. P0500 Vehicle Speed Sensor Malfunction No vehicle speed sensor signal to ECM under conditions a) and b). a) Park/neutral position switch is OFF. b) Vehicle is being driven. P0505 Idle Control System Malfunction Idle speed continues to vary greatly from the target speed. (2 trip detection logic) P0510 Closed Throttle Position Switch Malfunction The closed throttle position switch does not turn ON even once when the vehicle is driven. (2 trip detection logic) EG2–411 1MZ–FE ENGINE Trouble Area – DIAGNOSTIC TROUBLE CODE CHART MIL*1 Memory See Page • • • • • EGR valve stuck open EGR VSV open malfunction Open in EGR VSV circuit Short in EGR gas temp. senor circuit ECM • • • Three–way catalytic converter Open or short in heated oxygen sensor circuit Heated oxygen sensor EG2–534 • • • • Open or short in vehicle speed sensor circuit. Vehicle speed sensor Combination meter ECM EG2–537 • • • • IAC valve is stuck or closed Open or short in IAC valve circuit Air conditioner idle up VSV Air intake (hose loose) EG2–541 • • • Open in closed throttle position switch circuit. Closed throttle position switch ECM EG2–546 *1.... MIL does not light up O .... MIL lights up O .... MIL lights up, 0/D OFF indicator light blinks O *2.... MIL lights up only on USA specification vehicles. EG2–527 EG2–412 1MZ–FE ENGINE – DIAGNOSTIC TROUBLE CODE CHART DIAGNOSTIC TROUBLE CODE CHART (Cont’d) DTC No. Detection Item Diagnostic Trouble Code Detecting Condition P0720 Output Speed Sensor Circuit Malfunction (for Electronically Controlled Transaxle) DTC No. P0500 is detected. P0750 Shift Solenoid A Malfunction (Shift Solenoid Valve No.1) During normal driving the gear required by the ECM does not match the actual gear, (2 trip detection logic) P0753 Shift Solenoid A Electrical (Shift Solenoid Valve No,1) Open or short in shift solenoid valve No.1 circuit. P0755 Shift Solenoid6 Malfunction (Shift Solenoid Valve No.2) Same as for DTC No. P0750. P0758 Shift Solenoid B Electrical (Shift Solenoid Valve No.2) Open or short in shift solenoid valve No.2 circuit. Shift Solenoid E Malfunction (Shift Solenoid Valve SL) Lock–up does not occur when driving in the lock–up range (normal driving at 80 km/h [50 mph]), or lock–up remains ON in the lock–up OFF range. (2 trip detection logic) Shift Solenoid E Electrical (Shift Solenoid Valve SL) Open or short in shift solenoid valve SL circuit. (2 trip detection logic) P0770 P0773 EG2–413 1MZ–FE ENGINE Trouble Area – DIAGNOSTIC TROUBLE CODE CHART MIL* Memory See Page • Same as for DTC No. P0500. AX2–92 • • Shift solenoid valve No.1 is stuck open or closed. Valve body is blocked up or stuck. AX2–96 • • • Open or short in shift solenoid valve No.1 circuit. Shift solenoid valve No.1 ECM AX2–98 • Shift solenoid valve No.2 is stuck open or closed. AX2–96 • • • Open or short in shift solenoid valve No.2 circuit. Shift solenoid valve No.2 ECM • • Shift solenoid valve SL is stuck open or closed. Lock–up clutch 9 Valve body is blocked up or stuck. AX2–102 • • • Open or short in shift solenoid valve SL circuit. Shift solenoid valve SL ECM AX2–104 * – . . . . . MIL does not light up O . . . . .MIL lights up O . . . . MIL lights up, 0/D OFF indicator light blinks O AX2–98 EG2–414 1MZ–FE ENGINE – DIAGNOSTIC TROUBLE CODE CHART DIAGNOSTIC TROUBLE CODE CHART (Manufacturer Controlled) DTC No. Detection Item Diagnostic Trouble Code Detecting Condition P1300 Igniter Circuit Malfunction No IGF signal to ECM for 6 consecutive IGT signals during engine running. P1500 Starter Signal Circuit Malfunction No starter signal to ECM. P1600 ECM BATT Malfunction Open in back up power source circuit. P1605 Knock Control CPU Malfunction Engine control computer malfunction (for knock control). ”NC2” Revolution Sensor Circuit Malfunction (Direct Clutch Speed Sensor) Output of direct clutch speed sensor (NC2) is 300 rpm or less under conditions a) and b). (2 trip detection logic) a) Vehicle speed: 32 km/h (20 mph) or more b) Park/neutral position switch: OFF Linear Solenoid for Accumulator Pressure Control Circuit Malfunction (Shift Solenoid Valve SLN) After the engine is warmed up, the current flow to the shift solenoid valve SLN is 0.2 A or less for at least 1 sec. under condition a) or b). (2 trip detection logic) a) Engine speed: 500 rpm or more b) Park/neutral position switch: ON (P or N position) P1705 P1765 Two or more switches are ON simultaneously for ”N”, ”2” and ”L” position. (2 trip detection logic) P1780 Park/Neutral Position Switch Malfunction When driving under conditions a) and b)for 30 sec. or more, the park/neutral position switch is ON (N position). (2 trip detection logic) a) Vehicle speed: 70 km/h (44 mph) or more b) Engine speed: 1,500 – 2,500 rpm EG2–415 1MZ–FE ENGINE Trouble Area – DIAGNOSTIC TROUBLE CODE CHART MIL* Memory See Page • • • Open or short in IGF or IGT circuit from igniter to ECM. Igniter ECM EG2–550 • • • Open or short in starter signal circuit. Open or short in ignition switch or starter relay circuit, ECM EG2–557 • • Open in back up power source circuit. ECM EG2–559 • ECM EG2–561 • • • Open or short in direct clutch speed sensor circuit. Direct clutch speed sensor ECM • • • Open or short in shift solenoid valve SLN circuit. Shift solenoid valve SLN ECM AX2–112 • • • Short in park/neutral position switch circuit. Park/neutral position switch ECM EG2–562 *: – . . . . . MIL does not light up O . . . . MIL lights up O . . . . MIL lights up, 0/D OFF indicator light blinks O AX2–108 EG2–416 1MZ–FE ENGINE – SAFE CHART FAIL–SAFE CHART If any of the following codes is recorded, the ECM enters fail–safe mode. Fail–Safe Operation DTC No. • • Fail–safe Deactivation Conditions Ignition timing fixed at 5
BTDC. Injection time fixed Starting ............... 11.0 m sec. CTP Switch ON ....... 3.5 m sec. CTP Switch OFF ....... 6.3 m sec. Returned to normal condition P0110 Intake air temp. is fixed at 68
F (20
C). Returned to normal condition P0115 Engine coolant temp. is fixed at 176
F (80
C). Returned to normal condition P0100 P0120 P0135 P0141 P0155 P0325 P0330 P0720 P0753 P0758 VTA is fixed at 0
. The following condition must be repeated at least 2 times consecutively. When closed throttle position switch is ON: 0.1 V
VTA 0.95 V The heater circuit in which an abnormality is detected is turned off. Ignition switch OFF Max. timing retardation. Ignition switch OFF Gears are shifted according to the engine rpm and throttle angle. Returned to normal condition Power to the solenoid valve and lock–up solenoid valve is cut off. Returned to normal condition Power to the solenoid valve and lock–up solenoid valve is cut off. Returned to normal condition P0773 Power to the solenoid valve is cut off. Returned to normal condition P1300 Fuel cut IGF signal is detected for 6 consecutive ignitions. P1605 Max. timing retardation. Returned to normal condition P1766 Power to the solenoid valve is cut off. Returned to normal condition Back–up Function If there is trouble with the program in the ECM and ignition signals (IGT) are not output from the microcomputer, the ECM controls fuel injection and ignition timing at predetermined levels as a back–up function to make it possible to continue to operate the vehicle. Furthermore, the injection duration is calculated from the starting signal (STA) and the closed throttle position switch signal (IDL). Also, the ignition timing is fixed at 5
BTDC, without relation to the engine speed, HINT: If the engine is controlled by the back–up function, the malfunction indicator lamp lights up to warn the driver of the malfunction but the diagnostic trouble code is not output. EG2–417 1MZ–FE ENGINE – CHECK FOR INTERMITTENT PROBLEMS CHECK FOR INTERMITTENT PROBLEMS TOYOTA HAND–HELD TESTER only By putting the vehicle’s ECM in check mode, 1 trip detection logic is possible instead of 2 trip detection logic and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent problems. CLEAR DIAGNOSTIC TROUBLE CODES See page EG2–403 SET CHECK MODE See page EG2–403 PERFORM A SIMULATION TEST Using the symptom simulation (see page IN–24), shake and pull lightly on the wire harness, connector or terminals in the circuit indicated by the malfunction code. In this test, if the malfunction indicator lamp lights up, it indicates that the place where the wire harness, connector or terminals being pulled or shake has faulty contact. Check that point for loose connec– tions, dirt on the terminals, poor fit or other problems and repair as necessary. HINT: After cancelling out the diagnostic trouble code in memory and setting the check mode, if the malfunction indi– cator lamp does not go off after the engine is started, check thoroughly for faulty contacts, etc., then try the check again. If the malfunction indicator lamp still does not go off, check and replace the ECM. EG2–418 1MZ–FE ENGINE – CHECK FOR INTERMITTENT PROBLEMS CONNECTOR CONNECTION AND TERMINAL INSPECTION When checking for an open circuit or short circuit, it is impor– tant to check the connector connection and the condition of the terminals. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty con– tact in the connector, a connector terminal pulled out, etc. HINT: 1. A wire rarely breaks in the middle of it’s length. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators. 2. Faulty contact could be due to rusting of the connector terminals, to foreign materials entering the terminals or a drop in the contact pressure between the male and fe– male terminals of the connector. Simply disconnecting and reconnecting the connectors once changes the con– dition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector check, but the problem disappears after the check, them the cause is considered to be in the wire harness or con– nectors. SHORT CIRCUIT: This could be due to a short circuit between the wire harness and the body ground or to a short inside the switch, etc. HINT: When there is a short between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. EG2–419 1MZ–FE ENGINE – CHECK FOR INTERMITTENT PROBLEMS VISUAL CHECK AND CONTACT PRESSURE CHECK (a) Disconnect the connectors at both ends. (b) Check for rust or foreign material, etc. on the terminals of the connectors. (c) Check crimped portions for looseness or damage and check if the terminals are secured in the lock position. HINT: The terminals should not come out when pulled lightly. (d) Prepare a test male terminal and insert it in the female terminal, then pull it out. NOTICE: When testing a gold–plated female terminal, always use a gold–plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be ac– cessed from behind, take good care not to deform the connec– tor terminals. EG2–420 1MZ–FE ENGINE – BASIC INSPECTION BASIC INSPECTION When the normal code is displayed in the diagnostic trouble code check, troubleshooting should be performed in the order for all possible circuits to be considered as the causes of the problems. In many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine troubleshooting. 1 Is battery positive voltage 11 V or more when engine is stopped? YES 2 Charge or replace battery. Is engine cranked? Proceed to page ST–47, 63 and continue to troubleshoot. YES 3 Does engine start? YES 4 Go to step Check air filter. Remove air filter. Visually check that the air cleaner element is not damaged or excessively oily. If necessary, clean element with compressed air. First blow from inside thoroughly, then blow from outside of element. Repair or replace. Go to step EG2–421 1MZ–FE ENGINE 5 – BASIC INSPECTION Check idle speed. (1) Warm up engine to normal operating temper– ature. (2) Switch off all accessories. (3) Switch off air conditioning. (4) Shift transmission into ”N” position. (5) Connect the OBDII scan tool or TOYOTA hand–held tester to data link connector 3 on the vehicle. Use CURRENT DATA to check the engine idle speed. Idle speed: 650 – 750 rpm Proceed to matrix chart of problem symptoms on page EG2–435. 6 Check ignition timing. (1) Warm up engine to normal operating temper– ature. (2) Shift transmission into ”N” position. (3) Keep the engine speed at idle. (4) Using SST, connect terminals TE1 and E1 of data link connector 1. SST 09843–18020 (5) Using a timing light, connect the tester to check wire. (See page IG–81) Check ignition timing. Ignition timing: 10
BTDC at idle Proceed to page IG–80 and continue to troubleshoot. Proceed to matrix chart of problem symptoms on page EG2–435. EG2–422 1MZ–FE ENGINE 7 – BASIC INSPECTION Check fuel pressure. (1) Be sure that enough fuel is in the tank. (2) Turn ignition switch ON. (3) Connect the TOYOTA hand–held tester to data link connector 3 on the vehicle. (4) Use ACTIVE TEST mode to operate the fuel pump. Check that the pulsation damper screw rises up when the fuel pump operates. Proceed to page EG2–230 and continue to troubleshoot. 8 Check for spark. (1) Remove ignition coil (See page IG–89). . (2) Remove spark plug. (3) Install the spark plug to the ignition coil, and connect the ignition coil connector. (4) Ground the spark plug. (5) Disconnect injector connector. 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–87 and continue to troubleshoot. Proceed to matrix chart of problem systems on page EG2–435. EG2–423 1MZ–FE ENGINE PARTS LOCATION – PARTS LOCATION EG2–424 1MZ–FE ENGINE WIRING DIAGRAM – WIRING DIAGRAM EG2–425 1MZ–FE ENGINE – WIRING DIAGRAM EG2–426 1MZ–FE ENGINE – TERMINALS OF ECM TERMINALS OF ECM When measuring the voltage or resistance of the connector part of the ECM, always insert the test probe into the connector from the wire harness side. Terminal No. Symbol Connection Terminal No. E7–15 Symbol Connection IG T3 Igniter IG T2 Igniter Shift solenoid SLN Shift Solenoid No.2 Injector (No.6) Injector (No.5) Injector (No.4) Injector ( No.3 ) RSC IAC valve Injector (No.2) RSO IAC valve Injector (No.1) IGT1 Igniter Shift solenoid No.1 FPU Fuel pressure up VSV Igniter IGT4 Igniter Starter relay Park/Neutral position switch Shift solenoid SL E03 Oxygen sensor heater ground EG2–427 1MZ–FE ENGINE Terminal No. Symbol Connection – TERMINALS OF ECM Terminal No. Connection Symbol Igniter Heated oxygen sensor (Bank 2 Sensor 1) Igniter Engine coolant temp. sensor Intake air temp. sensor Throttle position sensor Sensor ground Power ground A/C idle–up VSV Power ground Throttle position sensor Malfunction indicator lamp Data link connector 1 Direct clutch speed sensor Intake air control valve VSV Crankshaft position sensor Mass air fIow meter Crankshaft position sensor Throttle position sensor Mass air flow meter Heated oxygen sensor heater (Bank 2 Sensor 1 ) Direct clutch speed sensor Heated oxygen sensor heater (Bank 1 Sensor 1) EGR VSV EG R gas temp. sensor Heated oxygen sensor (Bank 1 Sensor 1) Knock sensor 2 ECM ground Knock sensor 1 Camshaft position sensor Park/Neutral position switch Camshaft position sensor Electronically controlled transmission select switch Circuit opening relay EG2–428 1MZ–FE ENGINE – TERMINALS OF ECM TERMINALS OF ECM (Cont’d) Terminal No. Connection Symbol Terminal No. Symbol Connection A/C control assembly 0/D main switch Cruise control ECU A/C control assembly Defogger relay Taillight relay Park/Neutral position switch EFI Main relay EFI Main relay Vehicle speed sensor Stop light switch Stop light Tachometer Heated oxygen sensor heater (Bank 1 Sensor 2) Battery Heated oxygen sensor (Bank 1 Sensor 2) Park/Neutral position switch Data link connector 3 EG2–429 1MZ–FE ENGINE – MEMO – – EG2–430 1MZ–FE ENGINE – STANDARD VALUE OF ECM TERMINALS STANDARD VALUE OF ECM TERMINALS Symbols (Terminals No.) Wiring Color STD Voltage (V) Condition Always IG switch ON IG switch ON IG switch 0 N Throttle valve fully closed. IG switch ON Throttle valve fully open. IG switch ON Throttle valve fully closed. IG switch O N Throttle valve fully open. Idling, P or N Position, A/C switch off. Idling, Intake air temp. 20
C (68
F) Idling, Engine coolant temp. 80
C (176
F) Cranking IG switch 0 N Pulse generation (See page EG2–492) Idling Pulse generation (See page EG2–556) Idling IG switch ON Pulse generation (See page EG2–556) Pulse generation (See page EG2–505) Pulse generation (See page EG2–505) Idling Idling Idling IG switch ON Restarting at high engine coolant temp. Defogger switch and taillight switch ON. Defogger switch and taillight switch OFF. IG switch ON IG switch ON EG2–431 1MZ–FE ENGINE – STANDARD VALUE OF ECM TERMINALS STANDARD VALUE OF ECM TERMINALS (Cont’d) Symbols (Terminals No.) Wiring Color STD Voltage (V) Condition IG switch ON Disconnect (E7)of ECM connector Idling, A/C switch ON Idling, A/C switch OFF Maintain engine speed at 2,500 rpm for 2 mins. after warming up. Idling IG switch 0 N Idling IG switch ON Other shift position in ”P”, ”N” position IG switch ON Shift position in ”P”, ”N” position IG switch 0 N Rotate driving wheel slowly. IG switch ON IG switch ON Idling, A/C switch ON Idling, A/C switch OFF Idling, A/C switch ON Idling, A/C switch OFF EG2–432 1MZ–FE ENGINE – ENGINE OPERATING CONDITION ENGINE OPERATING CONDITION NOTICE: The values given below for ”Normal Condition” are representative values, so a vehicle may still be normal even if its value varies from those listed here. So do not decide whether a part is faulty or not solely according to the ”Normal Condition” here. CARB Mandated Signals TOYOTA hand–held tester display Measurement Item Normal Condition FUEL SYS #1 Fuel System Bank 1 OPEN: Air–fuel ratio feedback stopped CLOSED: Air–fuel ratio feedback operating Idling after warning up: CLOSED FUEL SYS #2 Fuel System Bank 2 OPEN: Air–fuel ratio feedback stopped CLOSED: Air–fuel ratio feedback operating Idling after warning up, CLOSED CALC LOAD Calculator Load: Current intake air volume as a proportion of max. intake air volume Idling: 12.9 – 25.2% Racing without load (2,500 rpm): 11.7 – 23.9% COOLANT TEMP Engine Coolant Temperature Sensor Value After warning up: 80 – 95
C (176 – 203
F) SHORT FT #1 Short–term Fuel Trim Bank 1 0 ± 20% LONG FT #1 Long–term Fuel Trim Bank 1 0 ± 20% SHORT FT #2 Short–term Fuel Trim Bank 2 0 ± 20% LONG FT #2 Long–term Fuel Trim Bank 2 0 ± 20% ENGINE SPD Engine Speed Idling: 700 ± 50 rpm VEHICLE SPD Vehicle Speed Vehicle Stopped: p km/h mph IGN ADVANCE Ignition Advance Ignition Timing of Cylinder No.1 Idling: BTDC 12 ±5
INTAKE AIR Intake Air Temperature Sensor Value Equivalent to Ambient Temp. MAF Air Flow Rate Through Mass Air Flow Meter Idling: 2.4 – 4.8 gm/sec Racing without load (2,500 rpm): 7.9 –.– 16.2 gm/sec THROTTLE POS Voltage Output of Throttle Position Sensor Calculated as a Percentage 0 V→ 0%, 5 V → 100% Throttle Fully Closed: 7 – 11% Fully Open: 65 – 75% 02S B1, S1 Voltage Output of Oxygen Sensor Bank 1, Sensor 1 Idling: 0.1 – 0.9 V If no conditions are specifically stated for ”Idling”, it means the shift lever is at N or P position, the A/C switch is OFF and all accessory switches are OFF. EG2–433 1MZ–FE ENGINE TOYOTA hand–held tester display – ENGINE OPERATING CONDITION Measurement Item Normal Condition O2FT B1, S1 Oxygen Sensor Fuel Trim Bank 1, Sensor 1 (Same as SHORT FT #1) O2S B1, S2 Voltage Output of Oxygen Sensor Bank 1, Sensor 2 Driving (50 km/h, 31 mph): 0.1 – 0.9 V O2S B2, S1 Voltage Output of Oxygen Sensor Bank 2, Sensor 1 Idling: 0.1 – 0.9 V O2FT B2, S1 Oxygen Sensor Fuel Trim Bank 2, Sensor 1 (Same as SHORT FT #2) 0 ± 20% 0 ± 20% TOYOTA Enhanced Signals TOYOTA hand–held tester display Measurement Item Normal Condition MISFIRE RPM Engine RPM for first misfire range Misfire 0: 0 RPM MISFIRE LOAD Engine load for first misfire range Misfire 0: 0 g/r INJECTOR Fuel injection time for cylinder No.1 Idling: 2.2 – 5.1 ms IAC DUTY RATIO Intake Air Control Valve Duty Ratio Opening ratio rotary solenoid type IAC valve Idling: 30 – 40% STARTER SIG Starter Signal Cranking: ON CTP SW Closed Throttle Position Switch Signal Throttle Fully Closed: ON A/C SIG A/C Switch Signal A/C ON: ON PNP SW Park/Neutral Position Switch Signal P or N position: ON ELCTRCL LOAD SIG Electrical Load Signal Defogger S/W ON: ON STOP LIGHT SW Stop Light Switch Signal Stop light switch ON: ON FC IDL Fuel Cut Idle: Fuel cut when throttle valve fully closed, during deceleration Fuel cut operating: ON FC TAU Fuel Cut TAU: Fuel cut during very light load Fuel cut operating: ON CYL #1  CY L #6 Ratio of revolution variation for each cylinder when variation is large IGNITION Ignition rate for all cylinders every 1,000 revolutions EGRT GAS EGR Gas Temperature Sensor Value EG R not operating: Temperature between intake air temp. and engine coolant temp. INTAKE CTRL VSV Intake Air Control Valve VSV Signal VSV operating: ON EGR SYSTEM EG R system operating condition Idling: OFF FUEL PRES UP VSV Fuel Pressure Up VSV Signal High temp. restarting: ON A/C CUT SIG A/C Cut Signal A/C S/W OFF: ON A/C IDLE U P VSV A/C Idle Up Signal A/C S/W ON & D position & headlight ON: ON 0 – 3,000 EG2–434 1MZ–FE ENGINE TOYOTA hand–held tester display – ENGINE OPERATING CONDITION Measurement Item Normal Condition TOTAL FT B1 Total Fuel Trim Bank 1: Average value for fuel trim system of bank 1 Idling: 0.8 – 1.2 TOTAL FT B2 Total Fuel Trim Bank 2: Average value for fuel trim system of bank 2 Idling: 0.8 – 1.2 02 LR B1, S1 Oxygen Sensor Lean Rich Bank 1, Sensor 1 Response time for oxygen sensor output to switch from lean to rich. Idling after warned up: 0 – 1,000 m sec. 02 LR B2, S1 Oxygen Sensor Lean Rich Bank 2, Sensor 1 Response time for oxygen sensor output to switch from lean to rich. Idling after warned up: 0 – 1,000 msec. 02 RL B1, S1 Oxygen Sensor Rich Lean Bank 1, Sensor 1 Response time for oxygen sensor output to switch from rich to lean. Idling after warned up: 0 – 1,000 msec. 02 RL B2, S1 Oxygen Sensor Rich Lean Bank 2, Sensor 1 Response time for oxygen sensor output to switch from rich to lean. Idling after warned up: 0 – 1,000 msec. *; If no conditions are specifically stated for ”Idling”, it means the shift lever is at Nor P position, the A/C switch is OFF and all accessory switches are OFF. EG2–435 1MZ–FE ENGINE – MATRIX CHART OF PROBLEM SYMPTOMS MATRIX CHART OF PROBLEM SYMPTOMS Does not start Engine does not crank No initial combustion No complete combustion Difficult to start Under normal condition Cold engine Hot engine High engine idle speed Engine stall Poor Drive– ability Poor Idling Low engine idle speed Rough idling Hunting Hesitation/Poor acceleration Surging Soon after starting During A/C operation AX2–81 IN–36 Engine control module (ECM) EG2–36 A/T faulty Compression AC–36 ST–47, 63 Starter and Starter relay EG2–586 Fuel pressure control VSV circuit Fuel pump control circuit ECM power source circuit Symptom Starter signal circuit Suspect area A/C signal circuit (Compressor circuit) EG2–575 See page EG2–565 EG2–557 When the malfunction code is not confirmed in the diagnostic trouble code check and the problem still can not be confirmed in the basic inspection, then proceed to this step and perform troubleshooting according to the numbered order given in the table below. EG2–436 1MZ–FE ENGINE – LOCATION OF CONNECTORS LOCATION OF CONNECTORS Location of Connectors in Engine Compartment C17 Camshaft Position Sensor Engine Coolant Temp. Sensor C18 Crankshaft Position Sensor Heated Oxygen Sensor ( Bank 1 Sensor 1) Data Link Connector 1 Heated Oxygen Sensor (Bank 2 Sensor 1) EGR Gas Temp. Sensor Idle Air Control Valve EG2–437 1MZ–FE ENGINE ign¿ter Injector No.4 Ignition Coil No.1 Ignition Coil No.6 Park/Neutral Position Switch – Injector No.1 LOCATION OF CONNECTORS Injector No.2¿ Ignition Coil No.4 Ignition Coil No.3 Ignition Coil No.2 Knock Sensor 1 Starter Igniter Injector No.6 Injector No.5 Injector No.3 Knock Sensor 2 Throttle Position Sensor Ignition Coil No.3 Mass Air Flow Meter VSV (for A/C Idle Up) EG2–438 1MZ–FE ENGINE – LOCATION OF CONNECTORS Location of Connectors in Engine Compartment (Cont’d) EG2–439 1MZ–FE ENGINE – LOCATION OF CONNECTORS Location of Connectors in Instrument Panel A/C Amplifier Engine Control Module Data Link Connector 2 Data Link Connector 3 Engine Control Module Engine Control Module Engine Control Module EG2–440 1MZ–FE ENGINE Heated Oxygen Sensor (Bank 1 Sensor 2) Ignition Switch – LOCATION OF CONNECTORS EG2–441 1MZ–FE ENGINE – LOCATION OF CONNECTORS Location of Connectors in Instrument Panel (Cont’d) EG2–442 1MZ–FE ENGINE Location of Connectors in Body – LOCATION OF CONNECTORS EG2–443 1MZ–FE ENGINE Wagon Fuel Pump – LOCATION OF CONNECTORS EG2–444 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0100 Mass Air Flow Circuit Malfunction CIRCUIT DESCRIPTION The mass air flow meter uses a platinum hot wire. The hot wire air flow meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake air bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire. This current flow is then measured as the output voltage of the air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit, with the power transistor controlled so that the potential of (A) and (B) remains equal to maintain the set tem– perature. DTC No. P0l00 Diagnostic Trouble Code Detecting Condition Open or short in mass air flow meter circuit with engine speed 4,000 rpm or less. Trouble Area • • • Open or short in mass air flow meter circuit Mass air flow meter ECM If the ECM detects diagnostic trouble code ”P01 00” it operates the fail safe function, keeping the ignition timing and injection volume constant and making it possible to drive the vehicle. EG2–445 1MZ–FE ENGINE – CIRCUIT INSPECTION HINT: After confirming DTC P01 00 use the OBDll scan tool or TOYOTA hand–held tester to confirm the mass air flow ratio from ”CURRENT DATA”. Mass Air Flow Value (gm/sec.) Malfunction 0.0 • • + B circuit open VG circuit open or short 271.0 or more • VG– circuit open WIRING DIAGRAM EG2–446 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART 1 Connect the OBDII scan tool or TOYOTA hand–held tester, and read value of mass air flow rate. Type II Go to step Type I 2 3 4 Check voltage of mass air flow meter power source. Check for open in harness and connector between EFI main relay and mass air flow meter. Check voltage between terminal VG and body ground. Check and replace ECM. Check for open and short in harness and connector between mass air flow meter and ECM. Repair or replace harness or connector. Replace mass air flow meter. 5 Check continuity between terminal VG– and body ground. Check and replace ECM. 6 Check for open in harness and connector between mass air flow meter and ECM. Repair or replace harness or connector. Replace mass air flow meter. EG2–447 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE 1 Connect the OBDII scan tool or TOYOTA hand–held tester, and read value of mass air flow rate. (1) Remove the fuse cover on the instrument panel. (2) Connect the OBDII scan tool or TOYOTA hand–held tester to the DLC 3. (3) Turn ignition switch ON and OBDII scan tool or TOYOTA hand–held tester main switch ON. (4) Start the engine. Read mass air flow rate on the OBDII scan tool or TOYOTA hand–held tester. Mass air flow rate Type I 2 Type II Type I 0.0 gm/sec. TypeII 271.0 gm/sec. or more Go to step Check voltage of mass air flow meter power source. (1) Disconnect the mass air flow meter connec– tor. (2) Turn ignition switch ON. Measure voltage between terminal 1 of mass air flow meter connector and body ground. Voltage: 9 –14 V Check for open in harness and connector between EFI main relay and mass air flow meter (See page IN–31). EG2–448 1MZ–FE ENGINE 3 – CIRCUIT INSPECTION Check voltage between terminal VG of ECM and body ground. (1) Remove glove compartment. (See page EG2–309) (2) Start the engine. Measure voltage between terminal VG of ECM and body ground while engine is idling. Voltage: 1.1 – 1.5 V (P position and A/C switch OFF) Check and replace ECM (See page IN–36). 4 Check for open and short in harness and connector between mass air flow meter and ECM (See page IN–31). Repair or replace harness or connector. Replace mass air flow meter. EG2–449 1MZ–FE ENGINE 5 – CIRCUIT INSPECTION Check continuity between terminal VG of ECM and body ground. Remove glove compartment (See page EG2–309). Check continuity between terminal VG– of ECM and body ground. Continuity (1
or less) Check and replace ECM (See page IN–36). 6 Check for– open in harness and connector between mass air flow meter– and ECM (See page IN–31). Repair or replace harness or connector. Replace mass air flow meter. EG2–450 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0101 Mass Air Flow Circuit Range Performance Problem CIRCUIT DESCRIPTION Refer to mass air flow circuit malfunction on page EG2–444. DTC No. P0101 Diagnostic Trouble Code Detecting Condition Trouble Area Conditions a) and b) continue with engine speed 900 rpm or less. (2 trip detection logic) a) Closed throttle position switch: ON b) Mass air flow meter output ) 2.2 V • Mass air flow meter WIRING DIAGRAM Refer to mass air flow circuit malfunction on page EG2–445. DIAGNOSTIC CHART 1 Are there any other codes (besides DTC P0101) being output? Replace mass air flow meter. YES Go to relevant diagnostic trouble code chart. EG2–451 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0110 Intake Air Temp Circuit Malfunction CIRCUIT DESCRIPTION The intake air temp. sensor is built into the 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 intake air temperature sensor is connected to the ECM (See next page). The 5V power source voltage in the ECM is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the intake air temperature sensor are connected in series. When the resistance value of the intake air temperature sensor changes in accordance with changes in the intake air temperature, the potential at terminal THA also changes. Based on this–signal, the ECM increases the fuel injection volume to improve driveability during cold engine operation. (Reference ) If the ECM records the diagnostic trouble code ”P0110”, it Intake Air Temp. °C (° F) operates the fail safe function in which the intake temperature is assumed to be 20C (68F). Intake Air Ter DTC No. P0110 Voltage M Trouble Area Diagnostic Trouble Code Detecting Condition Open or short in intake air temp. sensor circuit. Resistance (k
) • • • Open or short in intake air temp. sensor circuit. Intake air temp. sensor ECM Hint; After confirming DTC P01 10 use the OBDII scan tool or TOYOTA hand–held tester to confirm the intake air temperature from ”CURRENT DATA”. Temperature Displayed Malfunction – 40C (–40F) Open circuit 120C (248F) or more Short circuit EG2–452 1MZ–FE ENGINE WIRING DIAGRAM – CIRCUIT INSPECTION EG2–453 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART HINT; If diagnostic trouble codes ”P0110” (intake air temp. circuit malfunction), ”P0115” (engine coolant temp. circuit malfunction), ”P0120” (throttle position circuit malfunction) are output simultaneously, E2 (sensor ground) may be open. 1 Connect the OBDII scan tool or TOYOTA hand– held tester and read value of intake air temp. – 40C (– 40F) ......... Go to step 120C (248F) or more .. Go to step Check for intermittent problems. 2 3 Check for open in harness or ECM. Confirm good connection at sensor. If OK, replace mass air flow meter. Check for open in harness or ECM. Open in harness between ECM and intake air temp. sensor. Confirm good connection at ECM. If OK, replace ECM. 4 5 Check for short in harness and ECM. Replace mass air flow meter. Check for short in harness or ECM. Repair or replace harness or connector. Check and replace ECM. EG2–454 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE HINT: If diagnostic trouble codes ”P0110” (intake air temp. circuit malfunction), ”P0115” (engine coolant temp. circuit malfunction), ”P0120” (throttle position circuit malfunction) are output simultaneously, E2 (sensor ground) may be open. 1 Connect the OBDII scan tool or TOYOTA hand–held tester, and read value of intake air temperature. (1) Remove the fuse cover on the instrument panel. (2) Connect the OBDII scan tool or TOYOTA hand–held tester to the DLC 3. (3) Turn ignition switch ON and OBDII scan tool or TOYOTA hand–held tester main switch ON. Read temperature value on the OBDII scan tool or TOYOTA hand–held tester. Same as actual intake air temperature. If there is open circuit, OBDII scan tool or TOYOTA hand–held tester indicates – 40C (– 40 F). If there is short circuit, OBDII scan tool or TOYOTA hand–held tester indicates 120C (248F) or more.
– 40C (– 40 F) ........... Go to step 120 C (248F) or more ... Go to step  Check for intermittent problems. (See page EG2–417) EG2–455 1MZ–FE ENGINE 2 – CIRCUIT INSPECTION Check for open in harness or ECM. (1) Disconnect the mass air flow meter connec– tor. (2) Connect sensor wire harness terminals to– gether. (3) Turn ignition switch ON. Read temperature value on the OBDll scan tool or TOYOTA hand–held tester. Temperature value: 120C (248F) or more Confirm good connection at sensor. If OK, replace mass air flow meter. 3 Check for open in harness or ECM. (1) Remove glove compartment. (See page EG2–309) (2) Connect between terminals THA and E2 of ECM E8 connector. HINT: Mass air flow meter connector is disconnected. Before checking, do a visual and contact pres– sure check for the ECM connector. (See page EG2–418) (3) Turn ignition switch ON. Read temperature value on the OBDII scan tool or TOYOTA hand–held tester. Temperature value: 120C (248F) or more Open in harness between terminals E2 or THA, repair or replace harness. Confirm good connection at ECM. If OK, replace ECM.. EG2–456 1MZ–FE ENGINE 4 – CIRCUIT INSPECTION Check for short in harness and ECM. (1) Disconnect the mass air flow meter connec– tor. (2) Turn ignition switch ON. Read temperature value on the 0BDII scan tool or TOYOTA hand–held tester. Temperature value: – 40C (– 40F). Replace mass air flow meter. 5 Check for short in harness or ECM. (1) Remove glove compartment. (See page EG2–309) (2) Disconnect the E8 connector of ECM. HINT: Mass air flow meter connector is disconnected. (3) Turn ignition switch ON. Read temperature value on the OBDll scan tool or TOYOTA hand–held tester. Temperature value: –40C (–40F) Repair or replace harness or connector. Check and replace ECM (See page IN–36). EG2–457 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0115 Engine Coolant Temp Circuit Malfunction CIRCUIT DESCRIPTION A thermistor built into the engine coolant temperature sensor changes the resistance value according to the coolant temperature. The structure of the sensor and connection to the ECM is the same as in the intake air temp. circuit malfunction shown on page EG2–451. If the ECM records the diagnostic trouble code P01 15, it operates the fail safe function, keeping the engine coolant temp. at a constant 80
C (176
F). DTC No. Trouble Area Diagnostic Trouble Code Detecting Condition • P0115 Open or short in engine coolant temp. sensor circuit. • • Open or short in engine coolant temp. sensor circuit. Engine coolant temp. sensor. ECM HINT: After confirming DTC P01 15 use the OBDll scan tool or TOYOTA hand–held tester to confirm the engine coolant temperature from ”CURRENT DATA”. Temperature Displayed Malfunction – 40
C (– 40
F) Open circuit 120
C (248
F) or more Short circuit WIRING DIAGRAM EG2–458 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART HINT: If diagnostic trouble codes ”P0110” (intake air temp. circuit malfunction), ”P0115” (engine coolant temp. circuit malfunction) and ”P0120” (throttle position circuit malfunction) are output simultaneously, E2 (sensor ground) may be open. 1 Connect the OBDII scan tool or TOYOTA hand–held tester and read value of engine coolant temp. – 40
C (– 40
F) ......... Go to step 120
C (248
F) or more .. Go to step Check for intermittent problems. 2 Check for open in harness or ECM. Confirm good connection at sensor. If OK, replace engine coolant temp. sensor. 3 Check for open in harness or ECM. Open in harness between ECM and engine coolant temp. sensor. Confirm connection at ECM. If OK, replace ECM. 4 Check for short in harness and ECM. Replace engine coolant temp. sensor. 5 Check for short in harness or ECM. Repair or replace harness or connector. Check and replace ECM. EG2–459 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE HINT; If diagnostic trouble codes ”P0110” (intake air temp. circuit malfunction), ”P0115” (engine coolant temp. circuit malfunction), ”P0120” (throttle position circuit malfunction) are output simultaneously, E2 (sensor ground) may be open. 1 Connect the OBD II scan tool or TOYOTA hand–held tester, and read value of engine coolant temperature. (1) Remove the fuse cover on the instrument panel. (2) Connect the 0BDII scan tool or TOYOTA hand–held tester to the DLC 3. (3) Turn ignition switch ON and OBDII scan tool or TOYOTA hand–held tester main switch ON. Read temperature value on the OBDII scan tool or TOYOTA hand–held tester. Same as actual engine coolant temperature. If there is open circuit, OBD II scan tool or TOYOTA hand–held tester indicates – 40
C (– 40
F). If there is short circuit, OBD II scan tool or TOYOTA hand–held tester indicates 120
C (248
F) or more. – 40
C (– 40
F) .......... Go to step 120
C (248
F) or more . . Go to step Check for intermittent problems. (See page EG2–417) 2 3 EG2–460 1MZ–FE ENGINE 2 – CIRCUIT INSPECTION Check for open in harness or ECM. (1) Disconnect the engine coolant temp. sensor connector. (2) Connect sensor wire harness terminals to– gether. (3) Turn ignition switch ON. Read temperature value on the OBDII scan tool or TOYOTA hand–held tester. Temperature value: 120
C (248
F) or more Confirm good connection at sensor. If OK, replace engine coolant temp. sensor. 3 Check for open in harness or ECM. (1) Remove glove compartment. (See page EG2–309) (2) Connect between terminals THW and E2 of ECM E8 connector. HINT: Engine coolant temp. sensor connector is dis– connected. Before checking, do a visual and contact pressure check for the ECM connector. (See page EG2–418) (3) Turn ignition switch ON. Read temperature value on the OBDII scan tool or TOYOTA hand–held tester. Temperature value: 120
C (248
F) or more Open in harness between terminals E2 or THW, repair or replace harness. Confirm good connection at ECM. If OK, replace ECM . EG2–461 1MZ–FE ENGINE 4 – CIRCUIT INSPECTION Check for short in harness and ECM. (1) Disconnect the engine coolant temp. sensor connector. (2) Turn ignition switch ON. Read temperature value on the OBDII scan tool or TOYOTA hand–held tester. Temperature value: – 40
C (– 40
F) Replace engine coolant temp. sensor. 5 Check for short in harness or ECM. (1) Remove glove compartment. (See page EG2–309) (2) Disconnect the E8 connector of ECM. HINT: Engine coolant temp. sensor connector is dis– connected. (3) Turn ignition switch ON. Read temperature value on the OBDII scan tool or TOYOTA hand–held tester. Temperature value: –40
C (–40
F) Repair or replace harness or connector. Check and replace ECM (See page IN–36). EG2–462 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0116 Engine Coolant Temp Circuit Range Performance Problem CIRCUIT DESCRIPTION Refer to engine coolant temp. circuit malfunction on page EG2–457. DTC No. Diagnostic Trouble Code Detecting Condition P0116 20 min. or more after starting engine, engine coolant temp. sensor value is 30
C (86
F) or less. (2 trip detection logic) Trouble Area • • Engine coolant temp. sensor. Cooling system. DIAGNOSTIC CHART HINT: If diagnostic trouble codes ”P0115” (engine coolant temp. circuit malfunction) and ”P0116” (engine coolant temp. circuit range/ performance) are output simultaneously, engine coolant temp. sensor circuit may be open. Perform troubleshooting of diagnostic trouble code P0115 first. 1 Are there any other codes (besides DTC P0116) being output? Replace engine coolant temp. sensor. (See page EG2–282) YES Go to relevant diagnostic trouble code chart. EG2–463 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0120 Throttle Position Circuit Malfunction CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and detects the throttle valve opening angle. When the throt– tle valve is fully closed, the IDL contacts in the throttle posi– tion sensor are on, so the voltage at the terminal IDL of the ECM becomes 0V. At this time, a voltage of approximately 0.7 V is applied to terminal VTA of the ECM. When the throttle valve is opened, the IDL contacts go off and thus the power source voltage of approximately 12 V in the ECM is applied to the terminal IDL of the ECM. The voltage applied to the termi– nal VTA of the ECM increases in proportion to the opening angle of the throttle valve and becomes approximately 3.5 – 5.0 V when the throttle valve is fully opened. The ECM judges the vehicle driving conditions from these signals input from terminals VTA and IDL, and uses them as one of the condi– thins for deciding the air–fuel ratio correction, power increases correction and fuel–cut control etc. Diagnostic Trouble Code Detecting Condition DTC No. P0120 Condition a) or b) continues. a) VTA ( 0.1 V, and closed throttle position switch is OFF. b ) VTA ) 4.9 V Trouble Area • • • Open or short in throttle position sensor circuit. Throttle position sensor. ECM HINT: • If there is open circuit in IDL line, diagnostic trouble code P0120 does not indicate, • After confirming DTC P0120 use the OBDll scan tool or TOYOTA hand–held tester to confirm the throttle valve opening percentage and closed throttle position switch condition. Throttle valve opening position expressed as percentage Trouble Area Throttle valve fully closed Throttle valve fully open VC line open VTA line open or short 0% Approx. 99% Approx. 100% E2 line open EG2–464 1MZ–FE ENGINE WIRING DIAGRAM – CIRCUIT INSPECTION EG2–465 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART HINT: If diagnostic trouble codes P0110, P01 15 and P0120 are output simultaneously, E2 (sensor ground) may be open. TOYOTA hand–held tester Connect the TOYOTA hand–held tester and read the throttle valve opening percentage. Check for intermittent problems. Read closed throttle position switch condition. G o to step Check voltage of terminal VC. Go to step Check throttle position sensor. Replace throttle position sensor. Check voltage of terminal VTA and E2 of ECM. Check for open and short in harness and connector between ECM and throttle position sensor (VTA line). Check and replace ECM. Check voltage of terminal VC and E2 of ECM. Check for open in harness and connector between ECM and sensor (VC line). Check and replace ECM. EG2–466 1MZ–FE ENGINE – CIRCUIT INSPECTION OBDII scan tool (excluding TOYOTA hand–held tester) Connect the OBDII scan tool and read the throttle valve opening percentage. Check for intermittent problems. Check voltage of terminal IDL and E2 of ECM. Go to step Check voltage of terminal VC on wire harness side connector. G o to step Check throttle position sensor. Replace throttle position sensor. Check voltage of terminal VTA and E2 of ECM. Check for open and short in harness and connector between ECM and throttle position sensor (VTA line). Check and replace ECM. Check voltage of terminal VC and E2 of ECM. Check for open in harness and connector between ECM and sensor (VC line). Check and replace ECM. EG2–467 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE TOYOTA hand–held tester HINT: If diagnostic trouble codes P01 10, P01 15 and P0120 are output simultaneously, E2 (sensor ground) may be open. Connect the TOYOTA hand–held tester and read the throttle valve opening percentage. (1) Remove the fuse cover on the instrument panel. (2) Connect the TOYOTA hand–held tester to the DLC 3. (3) Turn ignition switch ON and TOYOTA hand– held tester main switch ON. Read the throttle valve opening percentage. Throttle valve Throttle valve opening position expressed as percentage Fully open Approx. 70% Fully closed Approx. 10% Check for intermittent problems (See page EG2–417). Read closed throttle position switch condition. (1) Remove the fuse cover on the instrument panel. (2) Connect the TOYOTA hand–held tester to the DLC 3. (3) Turn ignition switch ON and TOYOTA hand– held tester main switch ON. Read closed throttle position switch condition. Throttle valve Closed throttle position switch condition Fully open OFF Fully closed Go to step EG2–468 1MZ–FE ENGINE – CIRCUIT INSPECTION Check voltage between terminal VC of wire harness side connector and body ground. (1) Disconnect the throttle position sensor con– nector. (2) Turn ignition switch ON. Measure voltage between terminal VC of wire har– ness side connector and body ground. Voltage: 4.5 – 5.5 V Go to step Check throttle position sensor. Disconnect the throttle position sensor connector. Measure resistance between terminals 4, 3 and 1 of throttle position sensor. Terminals Throttle valve 1 –4 1 –3 Resistance 4.25 – 8.25 k
Fully closed 0.3 – 6.3 k
Fully open 3.5 – 10.3 k
Replace throttle position sensor. EG2–469 1MZ–FE ENGINE – CIRCUIT INSPECTION Check voltage between terminals VTA and E2 of ECM. (1) Remove glove compartment. (See page EG2–309) (2) Turn ignition switch ON. Measure voltage between terminals VTA and E2 of ECM. Throttle Valve Voltage Fully closed 0.3 – 0.8 V Fully open 2.7 – 5.2 V Check for open and short in harness and connector between ECM and throttle position sensor (VTA line) (See page IN–31). Check and replace ECM (See page IN–36). Check voltage between terminals VC and E2 of ECM. (1) Remove glove compartment. (See page EG2–309) (2) Turn ignition switch ON. Measure voltage between terminals VC and E2 of engine control module connector. Voltage: 4.5 – 5.5 V Check and replace ECM (See page IN–36). Check for open in harness and connector between ECM and sensor (VC line) (See page IN–31). EG2–470 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE OBD II scan tool (excluding TOYOTA hand–held tester) HINT: If diagnostic trouble codes P0110, P0115, and P0120 are output simultaneously, E2 (sensor ground) may be open. Connect the OBD II scan tool and read the throttle valve opening percentage (See page EG2–467, step 1 ). Check for intermittent problems. (See page EG2–417) Check voltage of terminal IDL and E2 of ECM. (1) Remove glove compartment. (See page EG2–309) (2) Turn ignition Switch ON. Measure voltage between terminals IDL and E2 of ECM. Throttle Valve Voltage Fully closed 0 – 3.0 V Fully open 9–14V Go to step Check voltage between terminal VC of wire harness side connector and body ground (See page EG2–468, step 3). Go to step Check throttle position sensor (See page EG2–468, step 4). Replace throttle position sensor. EG2–471 1MZ–FE ENGINE – CIRCUIT INSPECTION Check voltage between terminals VTA and E2 of ECM (See page EG2–469, step 5). Check for open and short in harness and connector between ECM and throttle position sensor (VTA line) (See page IN–31). Check and replace ECM (See page IN–36). Check voltage terminals VC and E2 of ECM (Seepage EG2–469, step 6). Check and replace ECM (See page IN–36). Check for open in harness and connector between ECM and sensor (VC line) (See page IN–31). EG2–472 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0121 Throttle Position Circuit Range Performance Problem CIRCUIT DESCRIPTION Refer to throttle position circuit malfunction on page EG2–463. DTC No. Diagnostic Trouble Code Detecting Condition P0121 When closed throttle position switch is ON, condition a) continues. (2 trip detection logic) a ) VTA ) 2.0 V Trouble Area • Throttle position sensor. DIAGNOSTIC CHART Are there any other codes (besides DTC P0121) being output? Replace throttle position sensor. YES Go to relevant diagnostic trouble code chart. EG2–473 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0125 Insufficient Coolant Temp for Closed Loop Fuel Control CIRCUIT DESCRIPTION To obtain a high purification rate for the C0, HC and NOx components of the exhaust gas, a three–way catalytic converter is used, but for the most efficient use of the three–way catalytic converter, the air–fuel ratio must be precisely controlled so that it is always close to the stoichiometric air–fuel ratio. The oxygen sensor has the characteristic whereby its output voltage changes suddenly in the vicinity of the stoichiometric air–fuel ratio. This characteristic is used to detect the oxygen concentration in the exhaust gas and provide feedback to the computer for control of the air–fuel ratio. When the air–fuel ratio becomes LEAN, the oxygen concentration in the exhaust increases and the oxygen sensor informs the ECM of the LEAN condition (small electromotive force: 0 V). When the air–fuel ratio is RICHER than the stoichiometric air–fuel ratio the oxygen concentration in the exhaust gas is reduced and the oxygen sensor informs the ECM of the RICH condition (large electromotive force:1V) The EMC judges by the electromotive force from the oxygen sensor whether the air–fuel ration is RICH or LEAN and controls the injection time accordingly. However, if malfunction of the oxygen sensor causes output of abnormal electromotive force, the EMC is unable to perform accurate air–fuel ration control. The main heated oxygen sensors include a heater which heats the Zirconia element. The heater is controlled by the EMC. When the intake air volume is low (the temperature of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. DTC No. P0125 Trouble Area Diagnostic Trouble Code Detecting Condition After the engine is warmed up, heated oxygen sensor output does not indicate RICH even once when conditions a) and b) continue for at least 2 minutes. a) Engine speed: 1,500 rpm or more b) Vehicle speed: 40 km/h (25 mph) or more • • Open or short in heated oxygen sensor circuit. Heated oxygen sensor. HINT: After confirming DTC P0125 use the 0BDll scan tool or TOYOTA hand–held tester to confirm voltage output of heated oxygen sensor from current data. If voltage output of heated oxygen sensor is 0 V, heated oxygen sensor circuit may be open or short. EG2–474 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Connect the OBDll scan tool or TOYOTA hand–held tester and read value for voltage output of heated oxygen sensor. Check and replace ECM. Check for open and short in harness and connector between ECM and heated oxygen sensor. Repair or replace harness or connector. Replace heated oxygen sensor. WIRING DIAGRAM EG2–475 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Connect the OBDII scan tool or TOYOTA hand–held tester and read value for voltage output of heated oxygen sensor. (1 ) Remove the fuse cover on the instrument panel. (2) Connect the OBDll scan tool or TOYOTA hand–held tester to the DLC 3. (3) Warm up engine to normal operating temper– ature. Read voltage output of heated oxygen sensor (bank 1,2 sensor 1) when engine is suddenly raced. Perform quick racing to 4,000 rpm three times us– ing accelerator pedal. Both heated oxygen sensors [(bank 1 sensor 1) (bank 2 sensor 1)] output a RICH signal (0.45 V or more) at least once. Check and replace ECM (See page IN–36). Check for open and short in harness and connector between ECM and heated oxygen sensor (See page IN–31). Repair or replace harness or connector. Replace heated oxygen sensor. EG2–476 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0130 P0150 Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 1 Bank 2 Sensor 1) CIRCUIT DESCRIPTION Refer to ”Insufficient coolant temp. for closed loop fuel control” on page EG2–473. DTC No. P0130 P0150 Diagnostic Trouble Code Detecting Condition Voltage output of heated oxygen sensor remains at 0,4 V or more, or 0,55 V or less, during idling after the engine is warmed up. (2trip detection logic) Trouble Area • • Heated oxygen sensor Fuel trim malfunction H I NT: Bank 1 refers to the bank that includes cylinder No.1. Bank 2 refers to the bank that does not include cylinder No,1. Sensor 1 refers to the sensor closer to the engine body. The heated oxygen sensor’s output voltage and the short–term fuel trim value can be read using the OBDll scan tool or TOYOTA hand–held tester. EG2–477 1MZ–FE ENGINE – CIRCUIT INSPECTION CONFIRMATION DRIVING PATTERN (1)Connect the TOYOTA hand–held tester to the DLC 3. (2)Switch the TOYOTA hand–held tester from normal mode to check mode (See page EG2–403). (3) Start the engine and warm it up with all accessory switches OFF. (4) After the engine is warmed up, drive at 50 – 65 km/h (31 – 40 mph) for 1 – 3 minutes to warm up the heated oxygen sensor. (5) After driving let the engine idle for 1 minute. HINT: If a malfunction exists, the MIL will light up during step (5) . NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction will not be possible. If you do not hove a TOYOTA hand–held tester, turn the ignition switch OFF after perform– ing steps (3) to (5), then perform steps (3) to (5) again. EG2–478 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check for open and short in harness and connector between ECM and heated oxygen sensor. Repair or replace harness or connector. Check heated oxygen sensor data. Check fuel trim system. Check output voltage of heated oxygen sensor. Perform confirmation driving pattern. Replace heated oxygen sensor. WIRING DIAGRAM EG2–479 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check for open and short in harness and connector between ECM and heated oxygen sensor (See page IN–31). Repair or replace harness or connector. Check for heated oxygen sensor data. (1) Remove the fuse cover on the instrument panel. (2) Connect the OBD II scan tool or TOYOTA hand–held tester to the DLC 3. (3) Warm up engine to normal operating temperature. Read the heated oxygen sensor output voltage and short–term fuel trim. Read the values for the same bank. Pattern Heated oxygen sensor output voltage Short–term fuel trim Lean condition (Changes at 0.55 V or less) Changes at about +20% Rich condition (Changes at 0.4 V or more) Changes at about –20% Except (1) and (2) (1),(2) Check fuel trim system. (See page EG2–486). Check the output voltage of heated oxygen sensor during idling. Warm up the heated oxygen sensor with the engine at 2,500 rpm for approx. 90 sec. Use the OBD II scan tool or TOYOTA hand–held tester read the output voltage of the heated ox– ygen sensor during idling. Heated oxygen sensor output voltage: Alternates repeatedly between less than 0.4 V and more than 0.55 V (See the adjacent table). Perform confirmation driving pattern. (See page EG2–477). Replace heated oxygen sensor. EG2–480 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0133 P0153 Heated Oxygen Sensor Circuit Slow Response (Bank 1 Sensor 1 Bank 2 Sensor 1) CIRCUIT DESCRIPTION Refer to ”Insufficient coolant temp. for closed loop fuel control” on page EG2–473. DTC No. P0133 P0153 Diagnostic Trouble Code Detecting Condition Response time for the heated oxygen sensor’s voltage output to change from rich to lean, or from lean to rich, is 1 sec. or more during idling after the engine is warmed up. (2 trip detection logic) Trouble Area • Heated oxygen sensor HINT: Bank 1 refers to the bank that includes cylinder No.1. Bank 2 refers to the bank that does not include cylinder No.1. Sensor 1 refers to the sensor closer to the engine body. DIAGNOSTIC CHART Are there any other codes (besides DTC P0133, P0153) being output? Replace heated oxygen sensor. YES Go to relevant diagnostic trouble code chart. EG2–481 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0135 P0141 P0155 Heated Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1 – Bank 1 Sensor 2 – Bank 2 Sensor 1) CIRCUIT DESCRIPTION Refer to ”Insufficient coolant temp. for closed loop fuel control” on page EG2–473. DTC No. P0135 P0141 P0155 Diagnostic Trouble Code Detecting Condition When the heater operates, heater current exceeds 2 A or voltage drop for the heater circuit exceeds 5 V. (2 trip detection logic) Heater current of 0.25 A or less when the heater operates. (2 trip detection logic) Trouble Area • • • Open or short in heater circuit of heated oxygen sensor. Heated oxygen sensor heater ECM H I NT: Bank 1 refers to the bank that includes cylinder No.1. Bank 2 refers to the bank that does not include 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. EG2–482 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check voltage of terminals HTR, HTS, HTL. Check and replace ECM. Check resistance of heated oxygen sensor heater. Replace heated oxygen sensor. Check and repair harness or connector between main relay and heated oxygen sensor and ECM. WIRING DIAGRAM EG2–483 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals HTR, HTS, HTL of ECM connector and body ground. (1) Remove glove compartment (See page EG2–309). (2) Turn ignition switch ON. Measure voltage between terminals HTR, HTS, HTL of ECM connector and body ground. Connect terminal HTR to bank 1 sensor 1. Connect terminal HTS to bank 1 sensor 2. Connect terminal HTL to. bank 2 sensor 1. Voltage: 9 –14 V Check and replace ECM (See page IN–36). Check resistance of heated oxygen sensor heater. Disconnect heated oxygen sensor connector. Measure resistance between terminals 1 and 2 of heated oxygen sensor connector. Resistance: 11 –16
at 20
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F) Replace heated oxygen sensor. Check and repair harness or connector between main relay and heated oxygen sensor and ECM. EG2–484 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0136 Heated Oxygen Sensor Circuit Malfunction (Bank 1 Sensor 2) CIRCUIT DESCRIPTION Refer to ”Insufficient coolant temp. for closed loop fuel control” on page EG2–473. Diagnostic Trouble Code Detecting Condition DTC No. P01 36 Voltage output of the heated oxygen sensor (bank 1 sensor 2) remains at 0.4 V or more or 0.5 V or less when the vehicle is driven at 50 km/h (31 mph) or more after the engine is warmed up. (2 trip detection logic) Trouble Area • Heated oxygen sensor HINT: Bank 1 refers to the bank that includes cylinder No.1. Sensor 2 refers to the sensor farther away from the engine body. DIAGNOSTIC CHART Are there any other codes (besides DTC P01 36) being output? YES Go to relevant diagnostic trouble code chart. Check for open and short in harness and connector between ECM and heated oxygen sensor. Repair or replace harness or connector. Check the output voltage of the heated oxygen sensor. Check that each connector is properly connected. Replace heated oxygen sensor. WIRING DIAGRAM Refer to page EG2–482 for the WIRING DIAGRAM. EG2–485 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Are there any other codes (besides DTC P0136) being output? YES Go to relevant diagnostic trouble code chart. Check for open and short in harness and connector between ECM and heated oxygen sensor (See page IN–31). Repair or replace harness or connector. Check the output voltage of heated oxygen sensor (bank 1 sensor 2). (1) Remove the fuse cover on the instrument panel. (2) Connect the OBDII scan tool or TOYOTA hand–held tester to the DLC 3. (3) After warming up the engine, race the engine at 2,500 rpm for 3 mins. Read the output voltage of heated oxygen sensor (bank 1 sensor 2) when racing the engine after 3 mins. have elapsed. Heated oxygen sensor output voltage: Alternates from 0.4 V or less to 0,5 V or more. Check that each connector is properly connected. Replace heated oxygen sensor. EG2–486 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0171 System too Lean (Fuel Trim) DTC P0172 System too Rich (Fuel Trim) CIRCUIT DESCRIPTION ”Fuel trim” refers to the feedback compensation value compared against the basic injection time. Fuel trim includes short–term fuel trim and long–term fuel trim. ”Short–term fuel trim” is the short–term fuel compensation used to maintain the air–fuel ratio at its ideal theoretical value. The signal from the heated oxygen sensor indicates whether the air–fuel ratio is RICH or LEAN compared to the ideal theoretical value, triggening a reduction in fuel volume if the air–fuel ratio is rich, and an increase in fuel volume if it is lean. ”Long–term fuel 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. If both the short–term fuel 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. DTC No. Diagnostic Trouble Code Detecting Condition P0171 When the air fuel ratio feedback is stable after engine warming up, the fuel trim is considerably in error on the RICH side. (2 trip detection logic) • • • • • • Air intake (hose loose) Fuel line pressure Injector blockage Heated oxygen sensor malfunction Mass air flow meter Engine coolant temp. sensor P0172 When the air fuel ratio feedback is stable after engine warming up, the fuel trim is considerably in error on the LEAN side. (2 trip detection logic) • • • • • Fuel line pressure Injector leak, blockage Heated oxygen sensor malfunction Mass air flow meter Engine coolant temp. sensor Trouble Area HINT; • When DTC P0171 is recorded, the actual air–fuel ratio is on the LEAN side. When DTC P0172 is recorded, the actual air–fuel ratio is on the RICH side, • Fuel trim applies separately to bank 1 and bank 2, so the ECM lights up the MIL if a problem occurs with either bank. • You can tell which bank is malfunctioning by looking at the short–term fuel trim and long–term fuel trim, thus allowing you to focus your inspection. • If the total of the short–term fuel trim value and long–term fuel trim value for each bank is within ± 25%, the system is functioning normally. EG2–487 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check air induction system. Repair or replace. Check heated oxygen sensor data. Check heated oxygen sensor. Check fuel pressure. Check and repair fuel pump, pressure regulator, fuel pipe line and filter. Check injector injection. Replace injector. Check mass air flow meter and engine coolant temp. sensor Repair or replace. Check for spark and ignition. Repair or replace. Check and replace ECM. EG2–488 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check air induction system (See page EG2–221). Repair or replace. Check for– heated oxygen sensor data. (1) Remove the fuse cover on the instrument panel. (2) Connect the OBDII scan tool or TOYOTA hand–held tester to the DLC 3. (3) Warm up engine to normal operating temper– ature. Read the heated oxygen sensor output voltage and short–term fuel trim. Read the values for the same bank. Pattern Heated oxygen sensor out put voltage Short–term fuel trim Lean condition Changes at 0.55 V or less Changes at about + 20% Rich condition Changes at 0.4 V or more Changes at about – 20% Check for heated oxygen sensor (See page EG2–476). EG2–489 1MZ–FE ENGINE – CIRCUIT INSPECTION Check fuel pressure. (1) Install the SST (pressure gauge) to the fuel filter output (See page EG2–231). SST 09268–45012 (2) Turn ignition switch ON. (3) Connect the TOYOTA hand–held tester to data link connector 3 on the vehicle. (4) Use ACTIVE TEST mode to operate the fuel pump. Connecting terminals B and FP of data link con– nector 1 allows the fuel pump to be operated. Measure the fuel pressure Fuel pressure: 265 – 304 kPa (2.7 – 3.1 kg f/cm2, 38 – 44 psi) Check and repair fuel pump, pressure regulator, fuel pipe line and filter. (See page EG2–230). Check injector injection. Remove the delivery pipe and injectors from the bank that has the malfunction (See page EG2–246). Check injection volume of injector (See page EG2–250) . Injection volume: 56 – 69 cm3/15 sec. (3.4 – 4.2 cu in.) Difference between each injector: Less than 6 cm3 (0.4 cu in.) Fuel drop (leakage): One drop or less per minute. Replace injector. EG2–490 1MZ–FE ENGINE – CIRCUIT INSPECTION Check mass air flow meter– and engine coolant temp. sensor (See page EG2–444, 457). Repair or replace. Check for spark and ignition (See page IG–84). Repair or replace. Check and replace ECM (See page IN–36). EG2–491 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0201 P0202 P0203 P0204 P0205 P0206 Injector Circuit Malfunction (Cylinder 1–6) CIRCUIT DESCRIPTION The injectors are located in the intake manifold. They inject fuel into the cylinders based on signals from the ECM. The ECM detects a malfunction of the injector circuit by counting the number of misfires of a specific cylinder. For an explanation of misfire detection requirements, see page DTC P0301. DTC No. P0201 P0202 P0203 P0204 P0205 P0206 Diagnostic Trouble Code Detecting Condition A specified cylinder misfire continuously. (2 trip detection logic) Trouble Area • • • • • Open or short in injector circuit Injector blockage, seized Ignition system Valve clearance not to specification Compression pressure See the Diagnostic Chart and Inspection Procedure under ”Misfiring”. EG2–492 1MZ–FE ENGINE – CIRCUIT INSPECTION WIRING DIAGRAM Reference INSPECTION USING OSCILLOSCOPE INJECTOR SIGNAL WAVEFORM • With the engine idling, measure between terminals #10 – #60 and E01 of ECM. HINT: The correct waveform appears as shown in the illustration below. EG2–493 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0300 Random Misfire Detected DTC P0301 P0302 P0303 P0304 P0305 P0306 Misfire Detected (Cylinder 1–6) CIRCUIT DESCRIPTION Misfire: The ECM uses the crankshaft position sensor and camshaft 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 occurs. DTC No. P0300 Diagnostic Trouble Code Detecting Condition Misfiring of multiple cylinders is detected during the same 200 or 1,000 revolutions. Trouble Area • • • • • • • • • Ignition system Injector Fuel line pressure EG R Compression pressure Valve clearance not to specification Valve timing Mass air flow meter Engine coolant temp. sensor P0301 For each 200 revolutions of the engine, misfiring is P0302 detected which can cause catalyst overheating. (This causes MIL to blink) P0303 P0304 For each 1,000 revolutions of the engine, misfiring is which causes emissions deterioration. P0305 detected (2 trip detection logic) P0306 HINT; When the code for a misfiring cylinder is recorded repeatedly but no Random Misfire code is recorded, it indicates that the misfires were detected and recorded at different times. EG2–494 1MZ–FE ENGINE WIRING DIAGRAM – CIRCUIT INSPECTION EG2–495 1MZ–FE ENGINE – FE ENGINE TROUBLESHOOTING – CIRCUIT INSPECTION DIAGNOSTIC CHART Check spark plug and spark of misfiring cylinder. Replace or check ignition system. Check voltage of ECM terminal for injector of failed cylinder. Go to step Check injector of misfiring cylinder. Replace injector. Check for open and short in harness and connector between injector and ECM. Check fuel pressure. Repair or replace fuel pump. Check injector injection. Replace injector. Check EGR system. Repair EGR system. Check mass air flow meter and engine coolant temp. sensor. Repair or replace. Check engine mechanical systems. EG2–496 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check spark plug and spark of misfiring cylinder. (1) Remove ignition coil (See page IG–87). (2) Remove spark plug. (1) Check the carbon deposits on electrode. (2) Check electrode gap. (1) No large carbon deposit present. Not wet with gasoline or oil. (2) Electrode gap: 1.1 – 1.3 mm (0.043 – 0.051 in.) (1) Install the spark plug to the ignition coil, and connect the ignition coil connector. (2) Ground the spark plug. (3) Disconnect injector connector. 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. Spark jumps across electrode gap. Replace or check ignition system (See page IG–84). Check voltage of ECM terminal for injector of failed cylinder. (1) Remove glove compartment (See page EG2–309) . (2) Turn ignition switch ON. Measure voltage between applicable terminal of ECM and body ground. Voltage: 9 – 14 V Go to step EG2–497 1MZ–FE ENGINE – CIRCUIT INSPECTION Check injector of misfiring cylinder. Disconnect injector connector (See page EG2–243) . Measure resistance of injector. Resistance: 5 – 23 Ω at 20
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F) Replace injector. Check for open and short in harness and connector between injector and ECM (See page IN–31). Check fuel pressure. (1) Install the SST (pressure gauge) to the fuel filter outlet. (See page EG2–231) . SST 09268–45012 (2) Turn ignition switch ON. (3) Connect the TOYOTA hand–held tester to the DLC3. (4) Use ACTIVE TEST mode to operate the fuel pump. HINT: The fuel pump can be operated by connecting terminals B and FP of data link connector 1. Measure the fuel pressure. Fuel pressure: 265 – 304 kPa (2.7 – 3.1 kgf/cm2, 38 – 44 psi) Check and repair fuel pump, pressure regulator, fuel pipe line and filter (See page EG2–230). EG2–498 1MZ–FE ENGINE – CIRCUIT INSPECTION Check injector injection. Remove delivery pipe and injectors (See page EG2–246) . Check injection volume of injector (See page EG2–250) . Injection volume: 56 – 69 cm3/15 sec. (3.4 – 4.2 cu in.) Difference between each injector: Less than 6 cm3 (0.4 cu in.) Fuel drop (leakage): One drop or less per minute. Replace injector. Check EGR system (See page EG2–207). Repair EGR system. Check mass air flow meter and engine coolant temp. sensor (See page EG2–444, 457). Repair or replace. Check engine mechanical systems. • Compression pressure (See page EG2–36 ). • Valve clearance (See page EG2–13 ). • Valve timing (See page EG2–52 ). EG2–499 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0325 P0330 Knock Sensor Circuit Malfunction (Knock Sensor 1 Knock Sensor 2) CIRCUIT DESCRIPTION Knock sensors are fitted one each to the right bank and left bank of the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it. DTC No. Trouble Area Diagnostic Trouble Code Detecting Condition P0325 No knock sensor 1 signal to ECM with engine speed 2,000 rpm or more. • • • Open or short in knock sensor 1 circuit. Knock sensor 1 (looseness). ECM P0330 No knock sensor 2 signal to ECM with engine speed 2,000 rpm or more. • • • Open or short in knock sensor 2 circuit. Knock sensor 2 (looseness). ECM If the ECM detects the above diagnosis conditions, it operates the fail safe function in which the corrective retard angle value is set to the maximum value. WIRING DIAGRAM EG2–500 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART HINT: DTC P0325 is for the right bank knock sensor circuit. DTC P0330 is for the left bank knock sensor circuit. Check knock sensor circuit. Type II G o to step Type I Check for open and short in harness and connector between EE1 connector and ECM. Repair or replace harness or connector. Check and replace ECM. Check for open and short in harness and connector between EE1 connector and knock sensor. Replace knock sensor. Repair or replace harness or connector. EG2–501 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Connect the OBDII scan tool or TOYOTA hand–held tester and check the knock sensor circuit. (1) Remove the fuse cover on the instrument panel. (2) Connect the OBDII scan tool or TOYOTA hand–held tester to the DLC 3. (3) Disconnect the wire to wire connector EE1. (4) Connect the terminals of the disconnected EE1 male connector and EE1 female as follows. Male connector ↔ Female connector Terminal 1↔ Terminal 2 Terminal 2↔ Terminal 1 (5) Turn ignition switch ON and OBDII scan tool or TOYOTA hand–held tester main switch ON. (6) After the engine is warmed up, perform quick racing (4,000 rpm) three times. Check the diagnostic trouble code. Type I Type II Type I DTC same as when vehicle brought in. P0325→ P0325 or P0330→ P0330 Type II DTC different to when vehicle brought in. P0325→ P0330 or P0330→ P0325 Go to step Check for open and short in harness and connector between EE1 connector and ECM (See page IN–31). Repair or replace harness or connector. Check and replace ECM (See page IN–36). EG2–502 1MZ–FE ENGINE – CIRCUIT INSPECTION Check for open and short in harness and connector between EE1 connector and knock sensor (See page IN–31). HINT: If DTC P0325 has changed to P0330, check the knock sensor circuit on the right bank side. If DTC P0330 has changed to P0325, check the knock sensor circuit on the left bank side. Repair or replace harness or connector. Replace knock sensor. Reference INSPECTION USING OSCILLOSCOPE • With the engine racing (4,000 rpm) measure be– tween terminals KNKR, KNKL of ECM and body ground. HINT: The correct waveform appears as shown i n the illustration on the left. • Spread the time on the horizontal axis, and confirm that period of the wave is 141 µ sec. (Normal mode vibration frequency of knock sen– sor: 7.1 KHz). HINT: If normal mode vibration frequency is not 7.1 KHz, the sensor is malfunctioning. EG2–503 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0335 Crankshaft Position Sensor Circuit Malfunction CIRCUIT DESCRIPTION Crankshaft position sensor (NE signal) consist of a signal plate and pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G22 signals, and the actual crankshaft angle and the engine speed by the NE signals. DTC No. Diagnostic Trouble Code Detecting Condition No crankshaft position sensor signal to ECM during cranking. (2 trip detection logic) P4335 No crankshaft position sensor signal to ECM during engine running. WIRING DIAGRAM Trouble Area • • • • Open or short in crankshaft position sensor circuit. Crankshaft position sensor. Starter ECM EG2–504 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART HINT: Perform troubleshooting of diagnostic trouble code P0335 first, If no trouble is found, trou– bleshoot the following mechanical systems. Check resistance of crankshaft position sensor. Replace sensor. Check for open and short in harness and connector between ECM and crankshaft position sensor. Repair or replace harness or connector. Inspect sensor installation and teeth of signal plate. Tighten the sensor. Replace signal plate. Check and replace ECM. EG2–505 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check resistance of crankshaft position sensor. Disconnect crankshaft position sensor connector. Measure resistance of crankshaft position sensor. Resistance Cold 1,630 – 2,740 Ω Hot 2,065 – 3,225 Ω ”Cold” is from –10
C (14
F) to 50
C (122
F) and ”Hot” is from 50
C (122
F) to 1 00
C (212
F). Reference INSPECTION USING OSCILLOSCOPE • During cranking or idling, check between terminals G22(+) and G22 (–) , NE(+) and NE (–) of engine control module. HINT: The correct waveforms appear as shown in the illustration on the left. Replace crankshaft position sensor. EG2–506 1MZ–FE ENGINE – CIRCUIT INSPECTION Check for open and short in harness and connector between ECM and crankshaft position sensor (See page IN–31). Repair or replace harness or connector. Inspect sensor installation and teeth of signal plate. Tighten the sensor. Replace signal plate. Check and replace ECM (See page IN–36). EG2–507 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0336 Crankshaft Position Sensor Circuit Range Performance CIRCUIT DESCRIPTION Refer to crankshaft position sensor circuit malfunction on page EG2–503. DTC No. Diagnostic Trouble Code Detecting Condition P0336 Deviation in crankshaft position sensor signal and camshaft position sensor signal. (2 trip detection logic) Trouble Area • • Mechanical system malfunction. (Skipping teeth of timing belt, belt stretched.) ECM DIAGNOSTIC CHART Check valve timing (Check for loose and jumping teeth of timing belt) (See page EG2–52). Check and replace ECM (See page IN–36). Adjust valve timing. (Repair or replace timing belt.) EG2–508 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0340 Camshaft Position Sensor Circuit Malfunction CIRCUIT DESCRIPTION Camshaft position sensor (G22 signal) consist of a signal plate and pick up coil. The G22 signal plate has one tooth, on its outer circumference and is mounted on the left bank camshafts. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up coil. The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34 signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G22 signal and the actual crankshaft angle and the engine speed by the NE signals. DTC No. P0340 Diagnostic Trouble Code Detecting Condition No camshaft position sensor signal to ECM during cranking. (2 trip detection logic) No camshaft position sensor signal to ECM during engine running. Trouble Area • • • • Open or short in camshaft position sensor circuit. Camshaft position sensor. Starter. ECM EG2–509 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check resistance of camshaft position sensor. Replace sensor. Check for open and short in harness and connector between ECM and camshaft position sensor. Repair or replace harness or connector. Inspect sensor installation. Tighten the sensor. Check and replace ECM. WIRING DIAGRAM EG2–510 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check resistance of camshaft position sensor. Disconnect camshaft position sensor connector. Measure resistance of camshaft position sensor. Resistance Cold 835 – 1,400
Hot 1,060 – 1,645
”Cold is form –10
C (140
F) to 50
C (122
F) and ”Hot” is form 50
C (122
F) to 100
C ( 212
F). Reference INSPECTION USING OSCILLOSCOPE • During cranking or idling, check between terminals G 22(+) and G22(–), NE(+) and NE (–) of engine control module. HINT: The correct waveforms appear as shown in the illustration on the left. Replace camshaft position sensor. EG2–511 1MZ–FE ENGINE – CIRCUIT INSPECTION Check for open and short in harness and connector between ECM and camshaft position sensor (See page IN–31). Repair or replace harness or connector. Inspect sensor installation. Tighten the sensor. Check and replace ECM (See page IN–36). EG2–512 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0401 Exhaust Gas Recirculation Flow Insufficient Detected CIRCUIT DESCRIPTION The EGR system recirculates exhaust gas, which is controlled to the proper quantity to suit the driving conditions, into the intake air mixture to slow down combustion, reduce the combustion temperature and reduce NOx emissions. The amount of EGR is regulated by the EGR vacuum modulator according to the engine load. If even one of the following conditions is fulfilled, the VSV is turned ON by a signal from the ECM. This results in atmospheric air acting on the EGR valve, closing the EGR valve and shutting off the exhaust gas (EGR cut–off). Under the following conditions, EGR is cut to maintain driveability. • Coolant temp. below 60
C (140
F). • During deceleration (throttle valve closed). • Light engine load (amount of intake air very small). • Engine racing. DTC No. Diagnostic Trouble Code Detecting Condition P0401 After the engine is warmed up and run at 80 km/h (50 mph) for 3 to 5 minutes, the EGR gas temperature sensor value does not exceed 40
C (104
F) above the ambient air temperature. (2 trip detection logic) Trouble Area • • • • • EGR valve stuck closed. Short in EGR VSV circuit. Open in EGR gas temp. sensor circuit. EGR hose disconnected. ECM EG2–513 1MZ–FE ENGINE – CIRCUIT INSPECTION SYSTEM CHECK DRIVING PATTERN Connect the OBDII scan tool or TOYOTA hand–held tester to the DLC 3. Start and warm up the engine with all accessories switched OFF. After the engine is warmed up, run the vehicle at 70 – 90 km/h (43 – 56 mph) for 3 min, or more. After driving, idle the engine for about 2 mins. After idling, check the ”READINESS TESTS”. If ”COMPL” (test completed) is displayed and the MIL does not light up, the system is normal. If ”INCPL” is displayed, run the vehicle again and check it. HINT: If a malfunction exists, the MIL will light up during step (4). EG2–514 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART TOYOTA hand–held tester Connect the TOYOTA hand–held tester and read value of EGR gas temperature. Go to step Check for open in harness or ECM. Confirm good connection at sensor. If OK, replace EGR gas temp. sensor. Check for open in harness or ECM. Open in harness between terminals E2 or THG. Repair or replace harness. Confirm connection at ECM, If OK, replace ECM. Check connection of vacuum hose, EGR hose. Repair or replace. Check the VSV for EG R, Go to step Check operation of the VSV for EG R. Replace VSV for EG R. Check for short in harness and connector between VSV and ECM. EG2–515 1MZ–FE ENGINE – CIRCUIT INSPECTION Check EGR Vacuum modulator. Repair or replace. Check EGR Valve. Repair or replace. Check value of EGR gas temp. sensor. Replace EGR gas temp. sensor. Check and replace ECM. EG2–516 1MZ–FE ENGINE – CIRCUIT INSPECTION OBD II scan tool (excluding TOYOTA hand–held tester) Check resistance of EGR gas temp. sensor. Check and replace EGR gas temp. sensor. Check for open in harness or ECM. Go to step Check for open in harness or ECM. Open in harness between terminals E2 or THG. Repair or replace harness. Confirm connection at ECM. If OK, replace ECM. Check connection of vacuum hose, EGR hose. Repair or replace. Check the VSV for EG R. Go to step Check operation of the VSV for EG R. Replace VSV for EG R. Check for open in harness and connector between J/B No,2 and ECM. EG2–517 1MZ–FE ENGINE – CIRCUIT INSPECTION Check EGR vacuum modulator. Repair or replace. Check EGR valve. Repair or replace. Check resistance of EGR gas temp. sensor. Replace EGR gas temp. sensor. Check and replace ECM. EG2–518 1MZ–FE ENGINE WIRING DIAGRAM – CIRCUIT INSPECTION EG2–519 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE TOYOTA hand–held tester Connect the TOYOTA hand–held tester and read value of EGR gas temperature value. (1) Remove the fuse cover on the instrument panel. (2) Connect the TOYOTA hand–held tester to the D LC 3. (3) Turn ignition switch ON and TOYOTA hand– held tester main switch ON. Read EGR gas temperature on the TOYOTA hand– held tester. EGR gas temp.: 10
C (50
F) or more. If there is an open circuit, the TOYOTA hand–held tester indicates 3.1
C (37.6
F). Go to step Check for open in harness or ECM. (1) Disconnect the EGR gas temp. sensor con– nector. (2) Connect sensor wire harness terminals to– gether. (3) Turn ignition switch ON. Read EGR gas temperature on the TOYOTA hand– held tester. EGR gas temp.: 159.3
C (318.7
F) Confirm good connection at sensor. If OK, replace EGR gas temp. sensor. EG2–520 1MZ–FE ENGINE – CIRCUIT INSPECTION Check for open in harness or ECM. (1) Remove glove compartment (See page EG2–309). (2) Connect between terminals THG and E2 of ECM E8 and E9 connectors. HINT: EGR gas temp. sensor connector is discon– nected. Before checking, do a visual check and contact pressure check for the ECM connector (See page EG2–418). Read EGR temperature on the TOYOTA hand–held tester. EGR gas temp.: 159.3
C (318.7
F) Open in harness between terminals E2 or THG. Repair or replace harness. Confirm connection at ECM. If OK, replace ECM. Check the connection of the vacuum hose, EGR hose (See page EG2–287). Repair or replace. EG2–521 1MZ–FE ENGINE – CIRCUIT INSPECTION Check the VSV for EGR. Select the active test mode on the TOYOTA hand– held tester. Check operation of EGR VSV, when it is operated by the TOYOTA hand–held tester. EGR system is OFF: The air from pipe E is flowing out through the air fitter. EGR system is ON: The air from pipe E is flowing out pipe G. Go to step EG2–522 1MZ–FE ENGINE – CIRCUIT INSPECTION Check operation of the VSV for EGR. (1) Remove EGR VSV. (2) Disconnect EGR VSV connector. (1) Measure resistance between terminals. (2) Measure resistance between each terminal and the body. (1 ) Resistance: 26 – 46
at 20
C (68
F) (2) Resistance: 1 M
or higher. Check operation of EGR VSV when battery voltage is applied, and is not applied to the terminals of EGR VSV connector. Battery voltage is applied: The air from pipe E flows out through the air filter. Battery voltage is not applied: The air from pipe E flows out through pipe G. Replace VSV for EGR. Check for short in harness and connector between VSV and ECM (See page IN–31). EG2–523 1MZ–FE ENGINE – CIRCUIT INSPECTION Check EGR vacuum modulator (See page EG2–210). Repair or replace. Check EGR valve (See page EG2–211). Repair or replace. Check value of EGR gas temp. sensor. (1) Connect the TOYOTA hand–held tester to the DLC3. (2) Turn ignition switch ON and TOYOTA hand– held tester main switch ON’ (3) Select the active test mode on the TOYOTA hand–held tester. (EGR system ON) (4) Race the engine at 4,000 rpm for 3 mins. Measure the EGR gas temp. while racing engine at 4,000 rpm. EGR gas temp. after 3 mins.: 140
C (284
F) or more Replace EGR gas temp. sensor. Check and replace ECM (See page IN–36). EG2–524 1MZ–FE ENGINE – CIRCUIT INSPECTION OBDII scan tool (excluding TOYOTA hand–held tester) Check resistance of EGR gas temp. sensor. Disconnect EGR gas temp. sensor connector. Measure resistance between terminals of EGR gas temp. sensor connector. Resistance: 600 k
or less. If there is open circuit, ohmmeter indicates 720 k
or more. Check and replace EGR gas temp. sensor (See page EG2–303). Check for open in harness or ECM. Disconnect EGR gas temp. sensor connector. Measure voltage between terminals of EGR gas temp. sensor wire harness side connector. Voltage: 4.5 – 5.5 V Go to step Check for open in harness or ECM. (1) Remove glove compartment (See page EG2– 309 ) . (2) Turn ignition switch ON. Measure voltage between terminals THG and E2 of ECM. HINT: EG R gas temp. sensor connector is dis– connected. Voltage: 4.5 – 5.5 V Open in harness between terminals E2 or THG. repair or replace harness. Confirm connection at ECM. If OK, replace ECM. EG2–525 1MZ–FE ENGINE – CIRCUIT INSPECTION Check connection of vacuum hose, EGR hose (See page EG2–287). Repair or replace. Check the VSV for EGR. (1) Remove glove compartment (See page EG2–309). (2) Turn ignition switch ON. Check EGR VSV function (1) Connect between terminal EGR of ECM and body ground. (ON) (2) Disconnect between terminal EGR of ECM and body ground (OFF). (1) VSV is ON: The air from pipe E flows out through the air filter. (2) VSV is OFF: The air from pipe E flows out through pipe G. Go to step Check operation of the VSV for– EGR (See page EG2–522, step Replace VSV for EGR. Check for open in harness and connector between J/B No.2 and ECM (See page IN–31). EG2–526 1MZ–FE ENGINE – CIRCUIT INSPECTION Check EGR vacuum modulator (See page EG2–210). Repair or replace. Check EGR valve (See page EG2–211). Repair or replace. Check resistance of EGR gas temp. sensor. (1) Disconnect EGR gas temp. sensor connector. (2) Start the engine and warm it up. (3) Disconnect EGR VSV connector. (4) Race the engine at 4,000 rpm for 3 mins. Measure the resistance of the EGR gas temp. sen– sor while racing the engine at 4,000 rpm. Resistance of EGR gas temp. sensor after 3 mins: 4.3 k
or Iess Resistance: 188.6 – 439.0 k
at 20
C (68
F) Replace EGR gas temp. sensor. Check and replace ECM (See page IN–36). EG2–527 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0402 Exhaust Gas Recirculation Flow Excessive Detected CIRCUIT DESCRIPTION Refer to Exhaust gas recirculation flow insufficient detected on page EG2–512. DTC No. Diagnostic Trouble Code Detecting Condition P0402 EG R gas temp. sensor value is high during EG R cut–off when engine is cold (Race engine at about 4,000 rpm without load so that vacuum is applied to port E). (2 trip detection logic) EG R valve is always open (2 trip detection logic) Trouble Area • • • • • EGR valve stuck open EGR VSV open malfunction Open in EGR VSV circuit Short in EGR gas temp. sensor circuit ECM See DTC P0401 for System Check Driving Pattern and Wiring Diagram. EG2–528 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART TOYOTA hand–held tester Connect the TOYOTA hand–held tester and read value of EGR gas temperature. G o to step Check for short in harness and ECM. Replace EGR gas temp. sensor. Check for short in harness or ECM. Repair or replace harness or connector. Check and replace ECM. Check the VSV for EG R. Check EGR valve. Check operation of the VSV for EG R. Replace VSV for EG R. Check for open in harness and connector between J/B No.2 and ECM. EG2–529 1MZ–FE ENGINE – CIRCUIT INSPECTION OBD II scan tool (excluding TOYOTA hand–held tester) Check resistance of EGR gas temp. sensor. Replace EGR gas temp. sensor. Check for short in harness and connector between EGR gas temp. sensor and ECM. Repair or replace harness or connector. Check the VSV for EG R. Check EGR valve. Check operation of the VSV for EG R. Replace VSV for EG R. Check for open in harness and connector between J/B No.2 and ECM. Repair or replace harness or connector. Check and replace ECM. EG2–530 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE TOYOTA hand–held tester Connect the TOYOTA hand–held tester and read EGR gas temperature value. (1) Remove the fuse cover on the instrument panel. (2) Connect the TOYOTA hand–held tester to the D LC 3. (3) Turn ignition switch ON and TOYOTA hand– held tester main switch ON. Read EGR gas temperature on the TOYOTA hand– held tester. EGR gas temp.: 150
C (302
F) or less. (Not immediately after driv– ing) If there is a short circuit, the TOYOTA hand–held tester indicates 159.3
C (318.7
F) . G o to step Check for short in harness and ECM. Disconnect the EGR gas temperature sensor con– nector. Rear EGR gas temperature on the TOYOTA hand– held tester. EGR gas temp.: 3.1
C (37.6
F) Replace EGR gas temp. sensor. EG2–531 1MZ–FE ENGINE – CIRCUIT INSPECTION Check for short in harness or ECM. (1) Remove glove compartment (See page EG2–309) . (2) Disconnect the E9 connector of ECM. HINT: EGR gas temp. sensor is disconnected. Read EGR gas temp. on the TOYOTA hand–held tester. EGR gas temp.: 3.1
C (37.6
F) Repair or replace harness or connector. Check and replace ECM (See page IN–36). Check the VSV for EGR. Select the active test mode on the TOYOTA hand– held tester. Check operation of EGR VSV, when it is operated by the TOYOTA hand–held tester. EGR system is OFF: The air from pipe E flows out through the air filter. EG R system is ON: The air from pipe E flows out through pipe G. Check EGR valve (See page EG2–211). EG2–532 1MZ–FE ENGINE – CIRCUIT INSPECTION Check operation of the VSV for EGR. (1) Remove EGR VSV. (2) Disconnect EGR VSV connector. (1) Measure resistance between terminals. (2) Measure resistance between each terminal and the body. (1) Resistance: 26 – 46
at 20
C (68
F) (2) Resistance: 1 M
or higher. Check operation of EGR VSV when battery voltage is applied, and not applied to the terminals of EGR VSV connector or not. Battery voltage is applied: The air from pipe E flows out through the air filter. Battery voltage is not applied: The air from pipe E flows out through pipe G. Replace VSV for EG R. Check for open in harness and connector between J/B No.2 and ECM (See page IN–31). EG2–533 1MZ–FE ENGINE – CIRCUIT INSPECTION OBDII scan tool (excluding TOYOTA hand–held tester) Check resistance of EGR gas temp. sensor. Disconnect EGR gas temp. sensor connector (See page EG2–303) . Measure resistance between terminals of EGR gas temp. sensor connector. Resistance: 2.5 k
or more. (Not immediately after driving) If there is short circuit, ohmmeter indicates 200
or less. Replace EG R gas temp. sensor. Check for short in harness and connector between EGR gas temp. sensor and ECM (See page IN–31).. Repair or replace harness or connector. Check the VSV for EGR (See page EG2–525, step Check EGR valve (See page EG2–211). Check operation of the VSV for EGR (See page EG2–532, step Replace VSV for EG R. Check for open in harness and connector between J/B No.2 and ECM (See page IN–31). Repair or replace harness or connector. Check and replace ECM (See page IN–36). EG2–534 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0420 Catalyst System Efficiency Below Threshold CIRCUIT DESCRIPTION The ECM compares the waveform of the oxygen sensor located before the catalyst with the waveform of the oxygen sensor located after the catalyst to determine whether or not catalyst performance has deteri– orated. Air–fuel ratio feedback compensation keeps the waveform of the oxygen sensor before the catalyst repeatedly changing back and forth from rich to lean. If the catalyst is functioning normally, the waveform of the oxygen sensor after the catalyst switches back and forth between rich and lean much more slowly than the waveform of the oxygen sensor before the catalyst. But when both waveforms change at a similar rate, it indicates that catalyst performance has deteriorated. DTC No. Diagnostic Trouble Code Detecting Condition P0420 After the engine is warmed up and the vehicle driven for 5 min. at 32 – 80 km/h (20 – 50 mph), the waveforms of the heated oxygen sensors, bank 1, 2 sensor 1 and bank 1 sensor 2 have the same amplitude. Trouble Area • • • Three–way catalytic converter Open or short in heated oxygen sensor circuit Heated oxygen sensor HINT: Only on U.S. vehicles does the MIL light up when a malfunction is detected. EG2–535 1MZ–FE ENGINE – CIRCUIT INSPECTION SYSTEM CHECK DRIVING PATTERN Connect the OBDII scan tool or TOYOTA hand–held tester to the DLC3. Start and warm up the engine with all accessories switched OFF. After the engine is warmed up, run the vehicle at 50 – 65 km/h (31 – 40 mph) for 5 – 10 min. HINT: If a malfunction exists, the MIL will light up during step (3) . EG2–536 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Are there any other codes (besides DTC P0420) being output? Check heated oxygen sensor. (See page EG2–476). Replace three–way catalytic converter. YES Go to relevant diagnostic trouble code chart. Repair or replace. EG2–537 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0500 Vehicle Speed Sensor Malfunction CIRCUIT DESCRIPTION The vehicle speed sensor outputs a 4–pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit inside the combination meter, it is then transmitted to the ECM. The ECM determines the vehicle speed based on the frequency of these pulse signals. DTC No. P0500 Diagnostic Trouble Code Detecting Condition No vehicle speed sensor signal to ECM under conditions (a) and (b). (a) Park/neutral position switch is OFF. (b) Vehicle is being driven. WIRING DIAGRAM Trouble Area • • • • Open or short in vehicle speed sensor circuit. Vehicle speed sensor Combination meter ECM EG2–538 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check operation of speedometer. Check speedometer circuit Check for short in harness and connector between terminal SP1 and body ground. Repair or replace harness or connector. Check voltage of terminal SP1. Check for open in harness and connector between J/B No.3 and ECM. Check for open in harness and connector between J/6 No.3 and combination meter. Repair or replace harness or connector. Check and replace ECM. EG2–539 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check operation of speedometer. Drive the vehicle and check if the operation of the speedometer in the combination meter is normal, HINT: The vehicle speed sensor is operating normally if the speedometer display is normal. Check speedometer circuit. See combination meter troubleshooting on page BE–66. Check for short in harness and connector between terminal SP1 of ECM and body ground. (1) Remove glove compartment (See page EG2–309). (2) Disconnect the E10 ECM connector. Check continuity between terminal SP1 of ECM and body ground. No continuity (1 M
or higher) Repair or replace harness or connector. Check voltage between terminal SP1 of ECM and body ground. Turn ignition switch ON. Measure voltage between terminal SP1 of ECM and body ground. Voltage: 9 –14 V Check for open in harness and connector between J/B No.3 and ECM (See page IN–31). EG2–540 1MZ–FE ENGINE – CIRCUIT INSPECTION Check for open in harness and connector between J/B No.3 and combination meter (See page IN–31). Repair or replace harness or connector. Check and replace ECM (See page IN–36). EG2–541 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0505 Idle Control System Malfunction CIRCUIT DESCRIPTION The rotary solenoid type IAC valve is located in front of the intake air chamber and intake air bypassing the throttle valve is directed to the IAC valve through a passage. In this way the intake air volume bypassing the throt– tle valve is regulated, controlling the engine speed. The ECM operates only the IAC valve to perform idle–up and provide feedback for the target idling speed and a VSV for idle–up control is also added (for air conditioning). DTC No. Diagnostic Trouble Code Detecting Condition P0505 Idle speed continues to vary greatly from the target speed. (2 trip detection logic) WIRING DIAGRAM Trouble Area • • • • IAC valve is stuck or closed open or short in IAC valve circuit Air conditioner idle up VSV Air intake (hose loose) EG2–542 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check air induction system. Repair or replace. Check A/C idle up VSV. Repair or replace. Check voltage terminals RSO, RSC. G o to step Check IAC valve. Replace IAC valve. Check for open and short in harness and connector between J/B No.2 and IAC valve, IAC valve and ECM. Check operation of the IAC valve. Check and replace ECM. Repair or replace IAC valve. EG2–543 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check air induction system (See page EG2–221). Repair or replace. Check A/C idle up VSV (See page EG2–570). Repair or replace. Check voltage terminals RSO, RSC. (1) Remove glove compartment (See page EG2–309). (2) Disconnect the ECM connector (P). (3) Turn ignition switch ON. Measure voltage between terminals RSO, RSC of ECM connector and body ground. Voltage: 9 –14 V Go to step EG2–544 1MZ–FE ENGINE – CIRCUIT INSPECTION Check IAC valve. Disconnect the IAC valve connector. Check continuity between terminals RSO, RSC and B of IAC valve connector. Terminals RSO and B Continuity (Reference value 10 – 30
) Terminals RSC and B Continuity (Reference value 10 – 30
) Replace IAC valve. Check for open and short in harness and connector between J/B No.2 and IAC valve, IAC valve and ECM (See page IN–31). EG2–545 1MZ–FE ENGINE – CIRCUIT INSPECTION Check operation of the IAC valve Remove IAC valve (See page EG2–274). (1) Connect the positive (+) lead from the bat– tery to terminal B and negative (–) lead to terminal RSC, and check that the valve is closed. (2) Connect the positive (+) lead from the bat– tery to terminal B and negative (–) lead to terminal RSO, and check that the valve is open. (1) The valve moves to close direction. (2) The valve moves to open direction. The ACTIVE TEST mode of the TOYOTA hand– held tester can be used to change the duty of the IAC valve as desired. Repair or replace IAC valve. Check and replace ECM (See page IN–36). EG2–546 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P0510 Closed Throttle Position Switch Malfunction CIRCUIT DESCRIPTION Refer to throttle Position Circuit on page EG2–463. DTC No. P0510 Diagnostic Trouble Code Detecting Condition The closed throttle position switch does not turn ON even once when the vehicle is driven, (2 trip detection logic) Trouble Area • • • Open in closed throttle position switch circuit. Closed throttle position switch. ECM HINT: After confirming DTC P0510 use the TOYOTA hand–held tester to confirm the closed throttle position switch signal from ”CURRENT DATA”. Throttle Valve Closed throttle position switch signal Malfunction Fully Closed OFF Open Circuit Fully Open WIRING DIAGRAM Short Circuit EG2–547 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART HINT: If diagnostic trouble codes ”P0110” (intake air temp. circuit malfunction), ”P0115” (engine coolant temp. circuit malfunction) and ”P0120” (throttle position circuit malfunction) are output simultaneously, E2 (sensor ground) may be open. TOYOTA hand–held tester Check for open in harness or ECM. Confirm good connection at sensor. If OK, replace throttle position sensor. Check for open in harness or ECM. Open in harness between ECM and throttle position sensor. Confirm connection at ECM. If OK, replace ECM. OBDII scan tool (excluding TOYOTA hand–held tester) Check for open in harness or ECM. Confirm good connection at sensor. If OK, replace throttle position sensor. Check for open in harness and connector between throttle position sensor and ECM. Open in harness between ECM and throttle position sensor. Confirm connection at ECM. If OK, replace ECM. EG2–548 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE HINT: If diagnostic trouble codes P0110, P0115 and P0120 are output simultaneously, E2 (sensor ground) may be open. TOYOTA hand–held tester Check for open in harness or ECM. (1) Remove the fuse cover on the instrument panel. (2) Connect the TOYOTA hand–held tester to the DLC 3. (3) Disconnect the throttle position sensor con– nector. (4) Connect sensor wire harness terminals be– tween terminals 1 and 2. (5) Turn ignition switch ON. Read CTP switch signal on the TOYOTA hand– held tester. CTP switch signal: ON Confirm good connection at sensor. If OK, replace throttle position sensor. Check for open in harness or ECM. (1) Remove glove compartment. (See page BO–309) (2) Connect between terminals IDL and E2 of ECM connectors. H I NT: Throttle position sensor connector is disconnected. Before checking, do a visual check and contact pressure –check for the connector. (See page EG2–418) (3) Turn ignition switch ON. Read CTP switch signal on the TOYOTA hand– held tester. CTP switch signal: ON Open in harness between ECM and throttle position sensor, repair or replace harness. Confirm connection at ECM. If OK, replace ECM. EG2–549 1MZ–FE ENGINE – CIRCUIT INSPECTION OBDII scan tool (excluding TOYOTA hand–held tester) Check for open in harness or ECM. (1) Disconnect the throttle position sensor con– nector. (2) Turn ignition switch ON. Measure voltage between terminals 1 and 2 of throttle position sensor connector. Voltage: 9 –14 V Confirm good connection at sensor. If OK, replace throttle position sensor. Check for open in harness and connector between throttle position sensor and ECM (See page IN–31). Open in harness between ECM and throttle position sensor. Confirm connection at ECM. If OK, replace ECM. EG2–550 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P1300 Igniter Circuit Malfunction CIRCUIT DESCRIPTION The ECM determines the ignition timing, turns on Tr1 at a predetermined angle (”CA) before the desired ignition timing and outputs an ignition signal (IGT) ”1” to the igniter. Since the width of the IGT signal is constant, the dwell angle control circuit in the igniter determines the time the control circuit starts primary current flow to the ignition coil based on the engine rpm and ignition timing one revolution ago, that is, the time the Tr2 turns on. When it reaches the ignition timing, the ECM turns Tr1 off and outputs the IGT signal ”0”. This turns Tr2 off, interrupting the primary current flow and generating a high voltage in the secondary coil which causes the spark plug to spark. Also, by the counter electromotive force generated when the primary current is interrupted, the igniter sends an ignition confirmation signal (IGF) to the ECM. The ECM stops. fuel injection as a fail safe function when the IGF signal is not input to the ECM. DTC No. Diagnostic Trouble Code Detecting Condition Trouble Area • P1300 No IGF signal to ECM for 6 consecutive IGT signals during engine running. WIRING DIAGRAM • • Open or short in IGF or IGT circuit from igniter to ECM. Igniter ECM EG2–551 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check voltage igniter power source. Check and repair igniter power source circuit. Check voltage between terminals 2 – 7 of igniter connector (12) and body ground. G o to step Check ignition coil. Replace ignition coil. Check for open and short in harness and connector between J/B No.1 and ignition coil, ignition coil and igniter. Check continuity between terminal 7 of igniter and body ground. Repair or replace harness or connector. Check voltage between terminal 8 of igniter connector (115) and body ground. Go to step Check for open and short in IGF circuit. Repair or replace harness or connector. Check and replace ECM. EG2–552 1MZ–FE ENGINE – CIRCUIT INSPECTION Check for open and short in IGT circuit. Repair or replace harness or connector. Check voltage between terminals IGT 1 – 6 of ECM and body ground. Replace igniter. Check and replace ECM. EG2–553 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminal 1 of igniter connector (12) and body ground. (1) Disconnect igniter connector (12) (2) Turn ignition switch ON. Connector 12 color is dark gray Measure voltage between terminal 1 of igniter connector 12 and body ground. Voltage: 9 –14 V Check and repair igniter power source circuit. Check voltage between terminals 2 – 7 of igniter connector and body ground. Measure voltage between terminals 2 – 7 of ig– niter connector (12) and body ground. Voltage: 9 – 14 V Go to step EG2–554 1MZ–FE ENGINE – CIRCUIT INSPECTION Check ignition coil. Disconnect ignition coil connector. (See page IG–87). Refer to the wiring diagram and inspect the igni– tion coil connected to the terminal which was without voltage in step (2) . Measure resistance between terminals of ignition coil connector. Resistance Cold 0.54 – 0.84
Hot 0.68 – 0.98
”Cold” is from –10
C (14
F) to 50
C (122
F) and ”Hot” is from 50
C (122
F) to 100
C (212
F). Replace ignition coil. Check for open and short in harness and connector between J/B No.1 and ignition coil, ignition coil and igniter (See page IN–31). Check continuity between terminal 7 of igniter connector (I15) and body ground. Disconnect igniter connector(I15) Connector (I15) is black. Check continuity between terminal 7 of igniter connector (I15) and body ground. Continuity (1
or less) Repair or replace harness or connector. EG2–555 1MZ–FE ENGINE – CIRCUIT INSPECTION Check voltage between terminal 8 of igniter connector (I15) and body ground. Turn ignition switch ON. Measure voltage between terminal 8 of igniter connector (I15) and body ground. Voltage: 4.5 – 5.5 V Go to step (7) Check for open and short in harness and connector between terminal IGF of ECM and igniter (See page IN–31). Repair or replace harness or connector. Check and replace ECM (See page IN–36). EG2–556 1MZ–FE ENGINE – CIRCUIT INSPECTION Check for open and short in harness and connector between terminals IGT1 – of ECM and igniter (See page IN–31). Repair or replace harness or connector. Check voltage between terminals IGT1 – 6 of ECM and body ground. Remove glove compartment (See page EG2–309). Leave igniter connector 115 disconnected. Measure voltage between terminals IGT1 – 6 of ECM and body ground when engine is cranked. Voltage: 0.5 – 1.0 v (Neither 0 v nor 5 v) Replace igniter. Check and replace ECM (See page IN–36). Reference INSPECTION USING OSCILLOSCOPE • During idling, check waveform between terminal IGT1, IGF and E1 of ECM. HINT: The correct waveform appears as shown in the illustration on the left, with rectangular waves. IGT2, IGT3, IGT4, IGT5 and IGT6 signal wave– forms are the same as the IGT1 signal waveform. EG2–557 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P1500 Starter Signal Circuit Malfunction CIRCUIT DESCRIPTION When the engine is cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery voltage is applied to terminal STA of the ECM. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after–start injection control. DTC No. P1500 Diagnostic Trouble Code Detecting Condition No starter signal to ECM. Trouble Area • • • Open or short in starter signal circuit. Open or short in ignition switch or starter relay circuit. ECM HINT: In this circuit, diagnosis can only be made in the check mode. DIAGNOSTIC CHART HINT: This diagnostic chart is based on the premise that the engine is cranked normally. If the engine is not cranked, proceed to the matrix chart of problem symptoms on page EG2–435. Connect the TOYOTA hand–held tester and check STA signal. Proceed to next circuit inspection shown on matrix chart. Check for open in harness and connector between ECM and starter relay. Repair or replace harness or connector. Check and replace ECM. WIRING DIAGRAM EG2–558 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Connect the TOYOTA hand–held tester and check STA signal. (1) Remove the fuse cover on the instrument panel. (2) Connect the TOYOTA hand–held tester to the DLC 3. (3) Turn ignition switch ON and TOYOTA hand– held tester main switch ON. Read STA signal on the TOYOTA hand–held tester while starter operates. Ignition Switch Position STA Signal OFF START Proceed to next circuit inspection shown on matrix chart (See page EG2–435). Check for open in harness and connector between ECM and starter relay (See page IN–31). Repair or replace harness or connector. Check and replace ECM (See page IN–36). EG2–559 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P1600 EMC BATT Malfunction CIRCUIT DESCRIPTION Battery voltage is supplied to terminal BATT of the ECM even when the ignition switch is OFF for use by the diagnostic trouble code memory and air–fuel ratio adaptive control value memory, etc. DTC No. P1600 Trouble Area Diagnostic Trouble Code Detecting Condition Open in back up power source circuit. • • Open in back up power source circuit. ECM HINT: If DTC P1600 appear, the ECM does not store another diagnostic trouble code. DIAGNOSTIC CHART Check voltage of terminal BATT. Check and replace ECM. Check EFI fuse. Check for short in all the harness and components connected to EFI fuse. Check and repair harness or connector between battery, EFI fuse and ECM. WIRING DIAGRAM EG2–560 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminal BATT of ECM connector and body ground. Remove glove compartment. (See page EG2–309) Measure voltage between terminal BATT of ECM connector and body ground. Voltage: 9 –14 V Check and replace ECM (See page IN–36). Check EFI fuse. Remove EFI fuse from J/B No.2. Check continuity of EFI fuse. Continuity Check for short in all the harness and components connected to EFI fuse. Check and repair harness or connector between battery, EFI fuse and ECM. EG2–561 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P1605 Knock Control CPU Malfunction CIRCUIT DESCRIPTION Refer to knock sensor 1 circuit malfunction on page EG2–499. DTC No. P1605 Trouble Area Diagnostic Trouble Code Detecting Condition Engine control computer malfunction. (for knock control) • ECM WIRING DIAGRAM Refer to knock sensor 1 circuit malfunction on page EG2–499. DIAGNOSTIC CHART Are there any other codes (besides DTC P1605) being output? Check and replace ECM (See page IN–36). YES Go to relevant diagnostic trouble code chart. EG2–562 1MZ–FE ENGINE – CIRCUIT INSPECTION DTC P1780 Park Neutral Position Switch Malfunction CIRCUIT DESCRIPTION The park/neutral position switch goes on when the shift lever is in the N or P shift position. When it goes on terminal NSW of the ECM is grounded to body ground via the starter relay thus the terminal NSW voltage becomes 0 V, When the shift lever is in the D, 2, L or R position, the park/neutral position switch goes off, so the voltage of ECM terminal NSW becomes battery voltage, the voltage of the ECM internal power source. If the shift lever is moved from the N position to the D position, this signal is used for air–fuel ratio correction and for idle speed control (estimated control), etc. DTC No. Diagnostic Trouble Code Detecting Condition Trouble Area Two or more switches are ON simultaneously for ”N”, ”2” and ”L” position. (2 trip detection logic) P1780 When driving under conditions a) and b) for 30 sec. or more the park/neutral position switch is ON ( N position). (2 trip detection logic) a) Vehicle speed; 70 km/h (44 mph) or more b) Engine speed; 1,500 – 2,500 rpm • • • Short in park/neutral position switch circuit. Park/neutral position switch. ECM HINT: After confirming DTC P1780 use the TOYOTA hand–held tester to confirm the PNP switch signal from ”CURRENT DATA”. EG2–563 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check park/neutral position switch. Replace park/neutral position switch. Check voltage between terminal NSW of ECM connector and body ground. Check and replace ECM. Check for open and short in harness and connector between ECM and park/neutral position switch. WIRING DIAGRAM EG2–564 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check park/neutral position switch. Disconnect park/neutral position switch connec– tor. Check continuity between each terminal shown below when the shift lever is positioned to each range. Continuity Terminal Shift Position Replace park/neutral position switch. Check voltage between terminal NSW of ECM connector and body ground. Remove glove compartment. (See page EG2–309) (1) Turn ignition switch ON. (2) Measure voltage between terminal NSW of ECM connector and body ground when the shift lever is positioned to the following positions. Shift lever position Voltage P or N L,2,D or R 9–14V Check and replace ECM (See page IN–36). Check for open and short in harness and connector between ECM and park/neutral position switch (See page IN–31). EG2–565 1MZ–FE ENGINE – CIRCUIT INSPECTION ECM Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery voltage is applied to the coil, closing the contacts of the EFI main relay and supplying power to the terminals + B and + B1 of the ECM. WIRING DIAGRAM EG2–566 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART Check voltage of ECM power source. Proceed to next circuit inspection shown on matrix chart . Check continuity between terminal E1 and body ground. Repair or replace harness or connector. Check EFI main relay. Replace EFI main relay. Check EFI fuse. Check for short in all the harness and components connected to EFI fuse. Check for open in harness and connector between main relay and battery, main relay and ECM. Repair or replace harness or connector. Check I G N fuse. Check for short in all the harness and components connected to IGN fuse. Check ignition switch. Replace ignition switch. Check for open in harness and connector between IG switch and main relay, main relay and body ground. EG2–567 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE Check voltage between terminals + B, + B1 and E1 of ECM connector. (1) Remove glove compartment. (See page EG2–309) (2) Turn ignition switch ON. Measure voltage between terminals + B, + 1B and E1 of ECM connector. Voltage: 9 –14 V Proceed to next circuit inspection shown on matrix chart (See page EG2–435). Check for open in harness and connector between terminal E1 of ECM and body ground (See page IN–31). Repair or replace harness or connector. EG2–568 1MZ–FE ENGINE – CIRCUIT INSPECTION Check EFI main relay. Remove EFI main relay from J/B No–2. Check continuity between terminals of EFI main relay shown below. Terminals 3 and 5 Terminals 1 and 2 Open Continuity (Reference value 72
) (1) Apply battery voltage between terminals 1 and 2. (2) Check continuity between terminals 3 and 5. Terminals 3 and 5 Continuity Replace EFI main relay. Check EFI fuse. Remove EFI fuse from J/B No.2. Check continuity of EFI fuse. Continuity Check for short in all the harness and components connected to EFI fuse. EG2–569 1MZ–FE ENGINE – CIRCUIT INSPECTION Check for open in harness and connector between main relay and battery, main relay and ECM (See page IN–31). Repair or replace harness or connector. Check IGN fuse. Remove IGN fuse from J/B No–1 Check continuity of IGN fuse. Continuity Check for short in all the harness and components connected to IGN fuse. Check ignition switch (See page BE–14). Replace ignition switch. Check for open in harness and connector between IG switch and main relay, main relay and body ground (See page IN–31). EG2–570 1MZ–FE ENGINE – CIRCUIT INSPECTION AC Idle Up Circuit CIRCUIT DESCRIPTION When the air conditioning operates (increased engine load), this circuit switch is on the VSV and increases the amount of bypass air to increase the idle speed, thus maintaining driveability. WIRING DIAGRAM EG2–571 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART TOYOTA hand–held tester Connect the TOYOTA hand–held tester and check operation of A/C idle–up VSV. Check and repair air hose and air pipe. Check A/C idle–up VSV. Replace A/C idle–up VSV. Check for open and short in harness and connector between EFI main relay and ECM. Repair or replace harness or connector. Check and replace ECM. OBDII scan tool (excluding TOYOTA hand–held tester) Check A/C idle–up VSV. Replace A/C idle–up VSV. Check voltage between terminal ACV and body ground. Check and repair harness or connector. Check air hose and air pipe. Repair or replace. Check and replace ECM. EG2–572 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE TOYOTA hand–held tester Connect the TOYOTA hand–held tester and check operation of A/C idle–up VSV. (1) Remove the fuse cover on the instrument panel. (2) Connect the TOYOTA hand–held tester to the DLC 3. (3) Turn ignition switch ON and TOYOTA hand– held tester main switch ON. (4) Select the active test mode on the TOYOTA hand–held tester. Check operation of A/C idle–up VSV when A/C idle–up VSV is operated by the TOYOTA hand– held tester. A/C idle–up VSV is ON: The air from port E is flowing out through port F. A/C idle–up VSV is OFF: The air does not flow from port E to port F. Check and repair air hose and air pipe. (See page EG2–295) EG2–573 1MZ–FE ENGINE – CIRCUIT INSPECTION Check A/C idle–up VSV. (1) Remove A/C idle–up VSV. (2) Disconnect A/C idle–up VSV connector. (1) Measure resistance between terminals. (2) Measure resistance between each terminal and the body. (1) Resistance: 22 – 42
at 20
C (68
F) (2) Resistance: 1 M
or higher Check operation of A/C idle–up VSV when battery positive voltage is applied to the terminals of A/C idle–up VSV connector or not. Battery positive voltage is applied: The air from pipe E is flowing out through pipe F. Battery positive voltage is not applied: The air from pipe E is not flowing out through pipe F. Replace A/C idle–up VSV. Check for open and short in harness and connector between EFI main relay and ECM (See page IN–31). Repair or replace harness or connector. Check and replace ECM (See page IN–36). EG2–574 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE OBDII scan tool (excluding TOYOTA hand–held tester) Check A/C idle–up VSV (See page EG2–573, step 2) Replace A/C idle–up VSV. Check voltage between terminal ACV of ECM connector and body ground. (1) Remove glove compartment. (See page EG2–309) (2) Turn ignition switch ON. Measure voltage between terminal ACV of ECM connector and body ground. Voltage: 9 –14 V Check for open and short in harness and connector between EFI main relay and ECM (See page IN–31). Check air hose and air pipe (See page EG2–295). Repair or replace. Check and replace ECM (See page IN–36). EG2–575 1MZ–FE ENGINE – CIRCUIT INSPECTION Fuel Pump Control Circuit CIRCUIT DESCRIPTION Fuel pump control The fuel pump is switched on (low voltage at terminal FC) when STA is on or while the NE signal is input to the ECM. In the diagram below, when the engine is cranked, current flows from terminal ST of the ignition switch to the starter relay coil, the starter relay switches on and current flows to coil L1 of the circuit opening relay. Thus the circuit opening relay switches on, power is supplied to the fuel pump and the fuel pump operates. When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil L2 of the circuit opening relay, the relay switches on and the fuel pump operates. While the NE signal is generated (engine running), the ECM keeps Tr ON (circuit opening relay ON) and the fuel pump also keeps operating. EG2–576 1MZ–FE ENGINE WIRING DIAGRAM – CIRCUIT INSPECTION EG2–577 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART TOYOTA hand – held tester Check fuel pump operation. Go to step Check for ECM power source circuit. Repair or replace. Check fuel pump. Repair or replace fuel pump. Check for open in harness and connector between terminal FP of DLC1 and fuel pump. fuel pump and body ground. Connect the TOYOTA hand – held tester and check operation of fuel pump. Go to step Check circuit opening relay. Replace circuit opening relay. Check voltage terminal FC. Check and replace ECM. Check for open in harness and connector between ER main relay and circuit opening relay, circuit opening relay and ECM. EG2–578 1MZ–FE ENGINE – CIRCUIT INSPECTION Check circuit opening relay. Replace circuit opening relay. Check voltage terminal 3 of circuit opening relay. Check for starter signal circuit. Check for open in harness and connector between terminal 6 of circuit opening relay and body ground, EG2–579 1MZ–FE ENGINE – CIRCUIT INSPECTION OBD ll scan tool (excluding TOYOTA hand – held tester) Check fuel pump operation. Go to step Check for ECM power source circuit. Repair or replace. Check fuel pump. Repair or replace fuel pump. Check for open in harness and connector between terminal FP of DLC1 and fuel pump, fuel pump and body ground. Check circuit opening relay. Replace circuit opening relay. Check voltage terminal FC. Check and replace ECM. Check for open in harness and connector between EFI main relay and ECM. Repair or replace harness or connector. Check voltage terminal 3 of circuit opening relay. Check for starter signal circuit. Check for open in harness and connector between terminal 6 of circuit opening relay and body ground. EG2–580 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE TOYOTA hand–held tester Check fuel pump operation. (1) Be sure that enough fuel is in the tank. (2) Turn ignition switch ON. (3) Using SST, connect terminals FP and + B of DLC 1, SST 09843–18020 Check that pulsation damper screw rises up when terminals are connected. Never make a mistake with the terminal connec– tion position as this will cause a malfunction. The pulsation damper screw rises up. Go to step Check for ECM power source circuit (See page EG2–565). Repair or replace. Check fuel pump (See page EG2–234). Repair or replace fuel pump. Check for open in harness and connector between terminal FP of DLC 1 and fuel pump, fuel pump and body ground (See page IN–31). EG2–581 1MZ–FE ENGINE – CIRCUIT INSPECTION Connect the TOYOTA hand–held tester and check operation of fuel pump. (1) Remove the fuse cover on the instrument panel. (2) Connect the TOYOTA hand–held tester to the DLC 3. (3) Turn ignition switch ON and TOYOTA hand– held tester main switch ON. (4) Select the active test mode on the TOYOTA hand–held tester. Check that pulsation damper screw rises up when fuel pump is on by TOYOTA hand–held tester. The pulsation damper screw rises up. Go to step EG2–582 1MZ–FE ENGINE – CIRCUIT INSPECTION Check circuit opening relay. Remove circuit opening relay from R/B No.6. (1) Apply battery voltage between terminals 2 and 4. (2) Measure voltage between terminals 1 and 4. Terminals 1 and 4 Same as battery Replace circuit opening relay. Check voltage between terminal FC of ECM and body ground. (1) Remove glove compartment (see page EG2–309). (2) Turn ignition switch ON. Measure voltage between terminal FC of ECM and body ground. Voltage: 9 –14 V Check and replace ECM (See page IN–36). Check for open in harness and connector between EFI main relay and circuit opening relay, circuit opening relay and ECM (See page IN–31). EG2–583 1MZ–FE ENGINE – CIRCUIT INSPECTION Check circuit opening relay. (1) Remove glove compartment (See page EG2–309). (2) Remove circuit opening relay from R/B No.6. (1) Apply battery voltage between terminals 3 and 6. (2) Check continuity between terminals 1 and 2. Terminals 1 and 2 Continuity Replace circuit opening relay. Check voltage between terminal 3 of R/B No.6 (for circuit opening relay) and body ground. Measure voltage between terminal 3 of R/B No.6 (for circuit opening relay) and body ground when engine is cranked. Voltage: 9 –14 V Check for starter signal circuit (See page EG2–557). Check for open in harness and connector between terminal 6 of R/6 No.6 (for circuit opening relay) and body ground (See page IN–31). EG2–584 1MZ–FE ENGINE – CIRCUIT INSPECTION OBDII scan tool (excluding TOYOTA hand–held tester) Check fuel pump operation (See page EG2–580, step Go to step Check for ECM power source circuit (See page EG2–565). Repair or replace. Check fuel pump (See page EG2–234). Repair or replace fuel pump. Check for open in harness and connector between terminal FP of DLC1 and fuel pump, fuel pump and body ground (See page IN–31). Check circuit opening relay. (1) Remove glove compartment (See page EG2–309). (2) Remove circuit opening relay from R/B No.6. Check continuity between terminals of circuit opening relay shown below. Terminals 1 and 2 Open Terminals 3 and 6 Continuity (Reference value 30
) (1) Apply battery voltage between terminals 3 and 6. (2) Check continuity between terminals 1 and 2. Terminals 1 and 2 Continuity Replace circuit opening relay. EG2–585 1MZ–FE ENGINE – CIRCUIT INSPECTION Check voltage between terminal FC of ECM and body ground (Seepage EG2–582, step 6 . Check and replace ECM (See page IN–36). Check for open in harness and connector between ER main relay and circuit opening relay, circuit opening relay and ECM (See page IN–31). Repair or replace harness or connector. Check voltage between terminal 3 of R/B No–6 (for circuit opening relay) and body ground (See page EG2–583, step 8 ). Check for starter signal circuit (See page EG2–557). Check for open in harness and connector between terminal 6 of circuit opening relay and body ground (See page IN–31). EG2–586 1MZ–FE ENGINE – CIRCUIT INSPECTION Fuel Pressure Control VSV Circuit CIRCUIT DESCRIPTION The ECM turns on a VSV (Vacuum Switching Valve) to draw the air into the diaphragm chamber of the pressure regulator if it detects that the temper– ature of the engine coolant is too high during engine starting. The air drawn into the chamber increases the fuel pressure to prevent fuel vapor lock at high engine temperature in order to help the engine start when it is warm. Fuel pressure control ends approx. 120 sec. after the engine is started. WIRING DIAGRAM EG2–587 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART TOYOTA hand–held tester Connect the TOYOTA hand–held tester and check operation of fuel pressure control VSV. Check and repair fuel pressure regulator. Check fuel pressure control VSV. Replace fuel pressure control VSV. Check for open and short in harness and connector between EFI main relay and ECM. Repair or replace harness or connector. Check and replace ECM. OBDII scan tool (excluding TOYOTA hand–held tester) Check fuel pressure control VSV. Replace fuel pressure control VSV. Check voltage between terminal FPU and body ground. Check and repair harness or connector. Check fuel pressure regulator. Repair or replace. Check and replace ECM. EG2–588 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE TOYOTA hand–held tester Connect the TOYOTA hand–held tester and check operation of fuel pressure control VSV. (1) Remove the fuse cover on the instrument panel. (2) Connect the TOYOTA hand–held tester to the DLC 3. (3) Turn ignition switch ON and TOYOTA hand– held tester main switch ON. (4) Select the active test mode on the TOYOTA hand–held tester. Check operation of fuel pressure control VSV when fuel pressure control VSV is operated by the TOYOTA hand–held tester. Fuel pressure control VSV is ON: The air from pipe E is flowing out through the air filter. Fuel pressure control VSV is OFF: The air from pipe E is flowing out through pipe G. Check and repair fuel pressure regulator (See page EG2–240). EG2–589 1MZ–FE ENGINE – CIRCUIT INSPECTION Check fuel pressure control VSV. (1) Remove fuel pressure control VSV. (2) Disconnect fuel pressure control VSV con– nector. (1) Measure resistance between terminals. (2) Measure resistance between each terminal and the body. (1) Resistance: 26 – 46
at 20
C (68
F) (2) Resistance: 1 M
or higher Check operation of fuel pressure control VSV when battery positive voltage is applied to the ter– minals of fuel pressure control VSV connector or not. Battery positive voltage is applied: The air from pipe E is flowing out through the air filter. Battery positive voltage is not applied: The air from pipe E is flowing out through pipe G. Replace fuel pressure control VSV. Check for open and short in harness and connector between EFI main relay and ECM (See page IN–31). Repair or replace harness or connector. Check and replace ECM (See page IN–36). EG2–590 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE OBDII scan tool (excluding TOYOTA hand–held tester) Check fuel pressure control VSV (See page EG2–589, step Replace fuel pressure control VSV. Check voltage between terminal FPU of ECM connector and body ground. (1) Remove glove compartment (See page EG2–309). (2) Turn ignition switch ON. Measure voltage between terminal FPU of ECM connector and body ground. Voltage: 9 –14 V Check for open and short in harness and connector between EFI main relay and ECM (See page IN–31). Check fuel pressure regulator (See page EG2–240). Repair or replace. Check and replace ECM (See page IN–36). EG2–591 1MZ–FE ENGINE – CIRCUIT INSPECTION AC Cut Control Circuit CIRCUIT DESCRIPTION This circuit cuts air conditioning operation during vehicle acceleration in order to increase acceleration performance. During acceleration with the vehicle speed at 25 km/h (16 mph) or less, engine speed at 1,600 rpm or less and throttle valve opening angle at 60
or more, the A/C magnet switch is turned OFF for several seconds. WIRING DIAGRAM EG2–592 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART TOYOTA hand–held tester Connect the TOYOTA hand–held tester and check operation of air conditioning cut control. Proceed to next circuit inspection shown on matrix chart. Check for open and short in harness and connector between ECM and A/C amplifier. Repair or replace harness or connector. Check voltage terminal ACT. Check and replace A/C amplifier. Check and replace ECM. OBDII scan tool (excluding TOYOTA hand–held tester) Check voltage terminal ACT. Check and replace ECM. Check for open and short in harness and connector between ECM and A/C amplifier. Repair or replace harness or connector. Check and replace A/C amplifier. EG2–593 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE TOYOTA hand–held tester Connect the TOYOTA hand–held tester and check operation of air conditioning cut control. (1) Remove the fuse cover on the instrument panel. (2) Connect the TOYOTA hand–held tester to the DLC3. (3) Turn ignition switch ON and TOYOTA hand– held tester main switch ON. (4) Start the engine and air conditioning switch ON. HINT: A/C magnet clutch is turned ON. (5) Select the active test mode on the TOYOTA hand–held tester. Check operation of A/C magnet clutch cut when air conditioning cut control is operated by the TOYOTA hand–held tester. A/C magnet clutch is turned OFF. Proceed to next circuit inspection shown on matrix chart (See page EG2–435). Check for open and short in harness and connector between ECM and A/C amplifier (See page IN–31). Repair or replace harness or connector. Check voltage between terminal ACT of ECM and body ground. (1) Remove glove compartment (See page EG2–309). (2) Start the engine. Measure voltage between terminal ACT of ECM connector and body ground when A/C switch is turned to ON and OFF. A/C switch condition Voltage 4.5 – 5.5 V OFF 0 –2 V Check and replace A/C amplifier. Check and replace ECM (See page IN–36). EG2–594 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE OBDII scan tool (excluding TOYOTA hand–held tester) Check voltage between terminal ACT of ECM and body ground (See page EG2–593, step 3 . Check and replace ECM (See page IN–36). Check for open and short in harness and connector between ECM and A/C amplifier (See page IN–31). Repair or replace harness or connector. Check and replace A/C amplifier. EG2–595 1MZ–FE ENGINE – CIRCUIT INSPECTION IACV Control VSV Circuit CIRCUIT DESCRIPTION This circuit opens and closes the IACV (Intake Air Control Valve) in response to the engine load in order to increase the intake efficiency (ACIS: Acoustic Control Induction System). When the engine speed is 3,700 rpm or less and the throttle valve opening angle is 60
or more, the ECM turns the VSV ON and closes the IACV. At all other times, the VSV is OFF, so the IACV is open. WIRING DIAGRAM EG2–596 1MZ–FE ENGINE – CIRCUIT INSPECTION DIAGNOSTIC CHART TOYOTA hand–held tester Connect the TOYOTA hand–held tester and check operation of IACV control VSV. Check for vacuum tank. Check IACV control VSV. Replace IACV control VSV. Check for open and short in harness and connector between EFI main relay and ECM. Repair or replace harness or connector. Check and replace ECM. OBDII scan tool (excluding TOYOTA hand–held tester) Check IACV control VSV. Replace IACV control VSV. Check voltage between terminal ACIS and body ground. Check and repair harness or connector. Check vacuum tank. Repair or replace. Check and replace ECM. EG2–597 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE TOYOTA hand–held tester Connect the TOYOTA hand–held tester and check operation of IACV control VSV. (1) Remove the fuse cover on the instrument panel. (2) Connect the TOYOTA hand–held tester to the D LC3. (3) Turn ignition switch ON and TOYOTA hand– held tester main switch ON. (4) Select the active test mode on the TOYOTA hand–held tester. Check operation of IACV control VSV when IACV control VSV is operated by TOYOTA hand–held tester. IACV control VSV is ON: The air from port E is flowing out through port F. IACV control VSV is OFF: The air from port E is flowing through the air filter. Check for EG2–277). vacuum tank (See page EG2–598 1MZ–FE ENGINE – CIRCUIT INSPECTION Check IACV control VSV. (1) Remove IACV control VSV. (2) Disconnect IACV control VSV connector. (1) Measure resistance between terminals. (2) Measure resistance between each terminal and the body. (1) Resistance: 26 – 46
at 20
C (68
F) (2) Resistance: 1 M
or higher. Check operation of IACV control VSV when bat– tery positive voltage is applied to the terminals of IACV control VSV connector or not. Battery positive voltage is applied: The air from pipe E is following out through pipe F. Battery positive voltage is not applied: The air from pipe E is flowing out through the air filter. Replace IACV control VSV. Check for open and short in harness and connector between EFI main relay and ECM (See page IN–31). Repair or replace harness or connector. Check and replace ECM (See page IN–36). EG2–599 1MZ–FE ENGINE – CIRCUIT INSPECTION INSPECTION PROCEDURE OBDII scan tool (excluding TOYOTA hand–held tester) Check IACV control VSV (See page EG2–598, step 2) Replace IACV control VSV. Check voltage between terminal ACIS of ECM connector and body ground. (1) Remove glove compartment (See page EG2–309). (2) Turn ignition switch ON. Measure voltage between terminal ACIS of ECM connector and body ground. Voltage: 9 –14 V Check for open and short in harness and connector between EFI main relay and ECM (Seepage IN–31). Check for vacuum tank (See page EG2–277). Repair or replace. Check and replace ECM (See page IN–36). IG–1 IGNITION SYSTEM – IGNITION SYSTEM IG–2 IGNITION SYSTEM – (5S–FE California) (5S–FE California) DESCRIPTION The engine control module (ECM) is programmed with data for optimum ignition timing unndr all operating conditions. Using data provided by sensors which monitor various engine functions (rpm, intake air volume, engine temperature, etc.), the ECM triggers the spark at precisely the right instant. The ECM monitors the engine condition by signals from each sensor, calculates the ignition timing and sends an ignition signal to the igniter. High voltage from the ignition is distributed to each spark plug in the appropriate order to generate a spark between the electrodes, which ignites the air–fuel mixture. IGNITER The igniter temporarily interrupts the primary current with the ignition signal (lGT signal) from the ECM and generates sparks at the spark plug. Also, as a fail–safe measure, when ignition occurs an ignition confirmation signal (IGF signal) is sent to the ECM. IGNITION COIL The ignition coil uses a closed core coil with the primary coil wrapped around the core and the secondary coil wrapped around the primary coil. This allows the generation of a high voltage sufficient to cause a spark to jump across the spark plug gap. DISTRIBUTOR This correctly distributes high voltage to the spark plug of each cylinder in the specified ignition order. PICKUP COILS The NE coil detects the crankshaft angle, and the G 1 and G2 coils detect the camshaft position. IG–3 IGNITION SYSTEM – (5S–FE California) PRECAUTION 1. Do not leave the ignition switch on for more than 10 minutes if the engine does not start. 2. With a tachometer connected to the system, con– nect the tester probe of the tachometer to terminal IG(–) of the data link connector 1. 3. As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of yours before use. 4. Never allow the tachometer terminals to touch ground as it could result in damage to the igniter and/or ignition coil. Do not disconnect the battery while the engine is running. 6. Check that the igniter is properly grounded to the body. IG–4 IGNITION SYSTEM – (5S–FE California) SYSTEM CIRCUIT OPERATION To maintain the most appropriate ignition timing, the ECM sends a control signal so that the igniter sends current to the ignition coil and the spark plugs produce a spark. IG–5 IGNITION SYSTEM – (5S–FE California) PREPARATION SST (SPECIAL SERVICE TOOLS) 09240–00020 Wire Gauge Set Air gap 09843–18020 Diagnosis Check Wire RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set 09200–00010 Engine Adjust Kit EQUIPMENT Spark plug cleaner Tachometer Timing light Ignition timing IG–6 IGNITION SYSTEM – (5S–FE California) ON–VEHICLE INSPECTION SPARK TEST CHECK THAT SPARK OCCURS (a) Disconnect the high–tension cord (from the ignition coil) from the distributor cap. (b) Hold the end approx. 12.5 mm (0.50 in.) from the body ground. (c) See if spark occurs while engine is being cranked. HINT: To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 1–2 seconds at time. If the spark does not occur, perform the test as fol– lows: SPARK TEST CHECK CONNECTION OF IGNITION COIL, IGNITER AND DISTRIBUTOR CONNECTOR CHECK RESISTANCE OF HIGH–TENSION CORD (See Page IG–7) Maximum resistance: 25 k
per cord CHECK POWER SUPPLY TO IGNITION COIL AND IGNITER 1. Turn ignition switch to ON. 2. Check that there is battery voltage at ignition coil positive (+) terminal. CHECK RESISTANCE OF IGNITION COIL See page IG–10) Resistance: Cold Hot Primary 0.36–0.55 0 0.45–0.65
Secondary 9.0–15.4 k
11.4–18.1 k
CHECK RESISTANCE OF SIGNAL GENERATOR (PICKUP COIL) See page (IG–12) Resistance: Cold HotG1 and G–125–200
160–235
G 2 and G–125–200
160–235
N E and G–155–250
190–290
Connect securely. BAD Replace the cord BAD Check wiring between ignition switch to ignition coil and igniter. BAD Replace the ignition coil. BAD Replace the distributor housing assembly. BAD CHECK AIR GAP OF DISTRIBUTOR (See page IG–11 ) Air gap: 0.2–0.5 mm (0.008–0.020 in.) BAD CHECK IGT SIGNAL FROM ECM (See page EG–344) BAD TRY ANOTHER IGNITER (s). Replace the distributor housing assembly. Check wiring between ECM, distributor and igniter, only then try another ECM. IG–7 IGNITION SYSTEM – (5S–FE California) HIGH–TENSION CORDS INSPECTION 1. DISCONNECT HIGH–TENSION CORDS FROM SPARK PLUGS Disconnect the high–tension cords at the rubber boot. Do not pull on the high–tension cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 2. DISCONNECT HIGH–TENSION CORD FROM IGNITION COIL 3. DISCONNECT HIGH–TENSION CORDS FROM DISTRIBUTOR CAP 4. INSPECT HIGH–TENSION CORD RESISTANCE Using an ohmmeter, measure the resistance. Maximum resistance: 25 k
per cord . If the resistance is greater than maximum, check the terminals. If necessary, replace the high–tension cord. 6. RECONNECT HIGH–TENSION CORDS TO DISTRIBUTOR CAP 6. RECONNECT HIGH–TENSION CORD TO IGNITION COIL 7. RECONNECT HIGH–TENSION CORDS TO SPARK PLUGS IG–8 IGNITION SYSTEM – (5S–FE California) SPARK PLUGS INSPECTION NOTICE: • Never use a wire brush for cleaning. • Never attempt to adjust the electrode gap on a used spark plug. • Spark plugs should be replaced every 100.000 km (60.000 miles). 1. DISCONNECT HIGH–TENSION CORDS FROM SPARK PLUGS Disconnect the high–tension cords at the rubber boot. Do not pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 2. INSPECT ELECTRODE Using a megger (insulation resistance meter), measure the insulation resistance. Standard correct insulation resistance: 10 M
or more If the resistance is less than specified, proceed to step 4. HINT: If a megger is not available, the following simple method of inspection provides fairly accurate results. Simple Method: (a) Quickly race the engine to 4,000 rpm 5 times. (b) Remove the spark plug. (See step 4) (c) Visually check the spark plug. If the electrode is dry ... OK If the electrode is wet ... Proceed to step 5 (d) Reinstall the spark plug. (See step 8) 3. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the 4 spark plugs. IG–9 IGNITION SYSTEM – (5S–FE California) 4. VISUALLY INSPECT SPARK PLUGS Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: PK20R11 for ND BKR6EP11 for NGK 5. INSPECT ELECTRODE GAP Maximum electrode gap for used spark plug: 1.3 mm (0.051 In.) If the gap is greater than maximum, replace the spark plug. Correct electrode gap for new spark plug: 1.1 m m (0.043 in.) NOTICE: if adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on the used plug. 6. CLEAN SPARK PLUGS If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/cm2, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. 7. REINSTALL SPARK PLUGS Using a 16 mm plug wrench, install the 4 spark plugs. Torque: 18 N–m (180 k9f–cm. 13 ft–lbf) 8. RECONNECT HIGH–TENSION CORDS T4 SPARK PLUGS IG–10 IGNITION SYSTEM – (5S–FE California) IGNITION COIL INSPECTION NOTICE: ’Cold’ and ’Hot’ in the following sentences ex– press the temperature of the coils themselves. ’Cold’ is from–10
C (14
F) to 50
C (122
F) and ’Hot’ is from 60
C (122” F) to 100
C (212
F). 1. DISCONNECT IGNITION COIL CONNECTOR 2. DISCONNECT HIGH–TENSION CORD FROM IGNITION COIL 3. INSPECT PRIMARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the positive (+) and negative (–) terminals. Primary coil resistance (Cold): 0.36–0.55
Primary coil resistance (Hot): 0.45–O.65
If the resistance is not as specified, replace the igni– tion coil. 4. INSPECT SECONDARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the positive (+) and high–tension terminals. Secondary coil resistance (Cold): 9.0–15.4 k
Secondary coil resistance (Hot): 11.4–18.1 k
If the resistance is not as specified, replace the igni– tion coil. 6. RECONNECT HIGH–TENSION CORD TO IGNITION COIL 6. RECONNECT IGNITION COIL CONNECTOR IG–11 IGNITION SYSTEM – (5S–FE California) DISTRIBUTOR INSPECTION NOTICE: ’Cold’ and “Hot’ in the following sentences ex– press the temperature of the coils themselves. ’Cold’ is from–10
C (14
F) to 50
C (122
F) and ’Hot’ is from 50
C (122
F) to 100
C (212
F). 1. REMOVE DISTRIBUTOR CAP Remove the 2 bolts, and disconnect the distributor cap from the distributor housing. 2. REMOVE ROTOR 3. REMOVE DUSTPROOF COVER 4. INSPECT AIR GAP Using SST (G1 and G2 pickups) and a feeler gauge (NE pickup), measure the air gap between the signal rotor and pickup coil projection. SST 09240–00020 for G 1 and G2 pickups Air gap: 0.2–0.5 mm (0.008–0.020 in.) If the air gap is not as specified, replace the distributor housing assembly. 6. DISCONNECT DISTRIBUTOR CONNECTOR 6. REMOVE DISTRIBUTOR HOUSING ASSEMBLY Remove the bolt, pull out the distributor housing. IG–12 IGNITION SYSTEM – (5S–FE California) 7. INSPECT SIGNAL GENERATOR (PICKUP COIL) RESISTANCE Using an ohmmeter, measure the resistance between terminals. Pickup coil resistance (Cold): G1 and GE) 125–200
G2 and G(–) 125–200
NE and G(–) 155–2500 Pickup coil resistance (Hot): G 1 and G(–) 160–235
G2 and G(–) 160–235
NE and G(–) 190–290
If the resistance is not as specified, replace the distributor housing assembly. 8. REINSTALL DISTRIBUTOR HOUSING ASSEMBLY (See steps 1 and 2 on pages IG–17 and 18) 9. RECONNECT DISTRIBUTOR CONNECTOR 10. REINSTALL DUSTPROOF COVER 11. REINSTALL ROTOR 12. REINSTALL DISTRIBUTOR CAP Install a new packing and distributor cap with the 2 bolts. 13. ADJUST IGNITION TIMING (See page IG–19) IGNITER INSPECTION (See Spark Test procedure on page IG–6) IG–13 IGNITION SYSTEM – (5S–FE California) DISTRIBUTOR COMPONENTS FOR REMOVAL AND INSTALLATION DISTRIBUTOR REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the Ignition switch Is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nacted from the battery. 2. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY IG–14 IGNITION SYSTEM – (5S–FE California) 3. REMOVE AIR CLEANER CAP, RESONATOR AND AIR CLEANER HOSE (a) Disconnect the intake air temperature sensor connec– tor. (b) Disconnect the air hose from the air cleaner hose. (c) Loosen the air cleaner hose clamp bolt. (d) Disconnect the 4 air cleaner cap clips. (e) Disconnect the air cleaner hose from the throttle body, and remove the air cleaner cap together with the resonator and air cleaner hose. 4. DISCONNECT DISTRIBUTOR CONNECTOR 5. DISCONNECT NIGH–TENSION CORD FROM IGNITION COIL 6. DISCONNECT HIGH–TENSION CORDS FROM SPARK PLUGS (a) Disconnect the high–tension cords from the cord clamps. (b) Disconnect the 4 high–tension cords from the spark plugs. Disconnect the high–tension cords at the rubber boot. Do not pull on the high–tension cords. NOTICE: Pulling on or bending the cords may damage the conductor Inside. 7. REMOVE DISTRIBUTOR (a) Remove the hold–down bolt, and pull out the distrib– utor. (b) Remove the 0–ring from the distributor housing. IG–15 IGNITION SYSTEM – (5S–FE California) COMPONENTS FOR DISASSEMBLY AND ASSEMBLY DISTRIBUTOR DISASSEMBLY (See Components for Disassembly and Assembly) 1. REMOVE DISTRIBUTOR CAP Remove the 2 bolts, distributor cap and packing. 2.REMOVE ROTOR Remove the 2 screws and rotor. IG–16 IGNITION SYSTEM – (5S–FE California) 3. REMOVE DUST PROOF COVER (a) Remove the dust proof seal. (b) Remove the dust proof cover. DISTRIBUTOR INSPECTION INSPECT SHAFT Turn the shaft and check that it is not rough or worn. If it feels rough or worn, replace the distributor hous– ing assembly. DISTRIBUTOR ASSEMBLY (See Components for Disassembly and Assembly) 1. INSTALL DUST PROOF COVER (a) Install the dust proof cover. (b) Install the dust proof.seal. IG–17 IGNITION SYSTEM – (5S–FE California) 2. INSTALL ROTOR (a) Align the hollow of the signal rotor with the protrusion of the rotor. (b) Install the rotor with the 2 screws. 3. INSTALL DISTRIBUTOR CAP (a) Install a new packing to the distributor housing. (b) Install the distributor cap with the 2 bolts. DISTRIBUTOR INSTALLATION (See Components for Removal and Installation) 1. SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft clockwise, and position the slit of the intake camshaft as shown in the illustration. IG–18 IGNITION SYSTEM – (5S–FE California) 2. INSTALL DISTRIBUTOR (a) Install a new O–ring to the housing. (b) Apply a light coat of engine oil on the 0–ring. (c) Align the cutout of the coupling with the line of the housing. (d) Insert the distributor, aligning the center of the flange with that of bolt hole on the cylinder head. (e) Lightly tighten the hold–down bolt. (f) Connect the high–tension cords to the clamp on the cylinder head cover. 3. CONNECT HIGH–TENSION CORDS TO SPARK PLUGS Firing order: 1–3–4–2 4. CONNECT HIGH–TENSION CORD TO IGNITION COIL 5. CONNECT DISTRIBUTOR CONNECTOR 6. INSTALL AIR CLEANER CAP, RESONATOR AND AIR CLEANER HOSE (a) Connect the air cleaner hose to the throttle body. (b) Install the air cleaner cap together with the resonator and air cleaner hose. (c) Connect the air hose to the air cleaner hose. (d) Connect the intake air temperature sensor connector. IG–19 IGNITION SYSTEM – (5S–FE California) 7. CONNECT AND ADJUST ACCELERATOR CABLE 8. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 9. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 10. CONNECT TACHOMETER AND TIMING LIGHT TO ENGINE Connect the test probe of a tachometer to terminal IGE) of the data link connector 1. NOTICE: • NEVER allow the tachometer terminal to touch ground as It could result In damage to the igniter and/or ignition coil. • As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of yours before use. . 11. ADJUST IGNITION TIMING (a) Using SST, connect terminals TE1 and E1 of the data link connector 1. SST 09843–18020 HINT: After engine speed is kept at 1,000–1,300 rpm for 5 seconds, check that it returns to idle speed. (b) Using a timing light, check the ignition timing. Ignition timing: 10
BTDC 0 idle (Transmission in neutral position) IG–20 IGNITION SYSTEM – (5S–FE California) (c) Loosen the hold–down bolt, and adjust by turning the distributor. (d) Tighten the hold–down bolt, and recheck the ignition timing. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) (e) Remove the SST. SST 09843–18020 12. FURTHER CHECK IGNITION TIMING Ignition timing: 0–10
BTDC 0 idle (Transmission in neutral position) HINT: The timing mark moves in a range between 0
and 10
. 13. DISCONNECT TACHOMETER AND TIMING LIGHT FROM ENGINE IG–21 IGNITION SYSTEM SERVICE SPECIFICATIONS SERVICE DATA Ignition timing w/ Terminals TE1 and E1 connected of DLC1 Firing order High–tension cord Resistance Spark plug Recommended spark plug Ignition coil Correct electrode gap Primary coil resistance Secondary coil resistance Distributor Air gap Pickup coil resistance TORQUE SPECIFICATIONS Part tightened Spark plug x Cylinder head Distributor x Cylinder head – (5S–FE California) IG–22 IGNITION SYSTEM – (5S–FE Except California) (5S–FE Except California) DESCRIPTION The engine control module (ECM) is programmed with data for optimum ignition timing under all operating conditions. Using data provided by sensors which monitor various engine functions (rpm, intake air volume, engine temperature, etc.), the ECM triggers the spark at precisely the right instant. The ECM monitors the engine condition by signals from each sensor, calculates the ignition timing and sends an ignition signal to the igniter. High voltage from the ignition is distributed to each spark plug in the appropriate order to generate a spark between the electrodes, which ignites the air–fuel mixture. IGNITER The igniter temporarily interrupts the primary current with the ignition signal (lGT signal) from the ECM and generates sparks at the spark plug. Also, as a fail–safe measure, when ignition occurs an ignition confirmation signal (IGF signal) is sent to the ECM. IGNITION COIL The ignition coil uses a closed core coil with the primary coil wrapped around the core and the secondary coil wrapped around the primary coil. This allows the generation of a high voltage sufficient to cause a spark to jump across the spark plug gap. DISTRIBUTOR This correctly distributes high voltage to the spark plug of each cylinder in the specified ignition order. The NE coil detects the crankshaft position, and the G coil detects the camshaft position. The NE coil detects the crankshaft position, and the G coil detects the camshaft position. IG–23 IGNITION SYSTEM – (5S–FE Except California) PRECAUTION 1. Do not leave the ignition switch on for more then 10 minutes if the engine does not start. 2. With a tachometer connected to the system, con– nect the test probe of the tachometer to terminal IG
of the data link connector 1. 3. As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of yours before use. 4. NEVER allow the tachometer terminals to touch ground as it could result in damage to the igniter and/or ignition coil. 6. Do not disconnect the battery while the engine is running. 6. Check that the igniter is properly grounded to the body. IG–24 IGNITION SYSTEM – (5S–FE Except California) SYSTEM CIRCUIT OPERATION To maintain the most appropriate ignition timing, the ECM sends a control signal so that the igniter sends current to the ignition coil and the spark plugs produce a spark. IG–25 IGNITION SYSTEM – (5S–FE Except California) PREPARATION SST (SPECIAL SERVICE TOOLS) 09843–18020 Diagnosis Check Wire RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set 09200–00010 Engine Adjust Kit EQUIPMENT Megger insulation resistance meter Insulation resistance meter Spark plug cleaner Tachometer Ignition timing Timing light SSM (SPECIAL SERVICE MATERIALS) 08826–00080 Seal packing or equivalent Ignition coil IG–26 IGNITION SYSTEM – (5S–FE Except California) ON–VEHICLE INSPECTION SPARK TEST CHECK THAT SPARK OCCURS (a) Disconnect the high–tension cords from the spark plugs. (See page IG–28) (b) Remove the spark plugs. (See page IG–28) (c) Install the spark plugs to the each high–tension cord. (d) Ground the spark plug. (e) Check if spark occurs while engine is being cranked. HINT: To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 1–2 seconds at a time. If the spark does not occur, perform the test as follows: SPARK TEST CHECK CONNECTION OF DISTRIBUTOR CONNECTORS CHECK RESISTANCE OF HIGH–TENSION CORD (See page IG–27) Maximum resistance: 25 k
per cord CHECK POWER SUPPLY TO IGNITION COIL 1. Turn ignition switch ON. 2. Check that there is battery voltage at ignition coil positive (+) terminal. CHECK RESISTANCE OF IGNITION COIL (See page IG–30) Resistance: Cold Hot Primary 0.36–0.55
0.45–0.65
Secondary 9.0–15.4 k
11.4–18.1 k
CHECK RESISTANCE OF SIGNAL GENERATOR (PICKUP COIL) (See page IG–31) Resistance: Cold Hot G (+) and IG (–) 185–275
240–325
N E (+) and NE (–) 370–550
475–650
Connect securely. BAD Replace the cord (s) . BAD Check wiring between ignition switch and ignition coil. BAD Replace the ignition coil. BAD Replace distributor housing assembly. BAD CHECK AIR GAP OF DISTRIBUTOR (See page IG–30) Air gap: 0.2–0.4 mm (0.008–0.016 in.) BAD CHECK IGT SIGNAL FROM ECM (See page EG–344) BAD TRY ANOTHER IGNITER Replace the distributor housing assembly. Check wiring between ECM, distributor and igniter, and then try another ECM. IG–27 IGNITION SYSTEM – (5S–FE Except California) HIGH–TENSION CORDS INSPECTION 1. DISCONNECT HIGH–TENSION CORDS FROM SPARK PLUGS Disconnect the high–tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 2. DISCONNECT HIGH–TENSION CORDS FROM DISTRIBUTOR CAP 3. INSPECT HIGH–TENSION CORD RESISTANCE Using an ohmmeter, measure the resistance. Maximum resistance: 25 k
per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the high–tension cord. 4. RECONNECT HIGH–TENSION CORDS TO DISTRIBUTOR CAP 5. RECONNECT HIGH–TENSION CORDS TO SPARK PLUGS . IG–28 IGNITION SYSTEM – (5S–FE Except California) SPARK PLUGS INSPECTION NOTICE: • • Never use e wire brush for cleaning. Never attempt to adjust the electrode gap on a used spark plug. • Spark plugs should be replaced every 100.000 km (60.000 miles). 1. DISCONNECT HIGH–TENSION CORDS FROM SPARK PLUGS 2. INSPECT ELECTRODE Using a megger (insulation resistance meter), measure the insulation resistance. Standard correct insulation resistance: 10 M
or more If the resistance is less than specified, proceed to step 3. HINT: If a megger is not available, the following simple method of inspection provides fairly accurate results. Simple Method: (a) Quickly race the engine to 4,000 rpm 5 times. (b) Remove the spark plug. (See step 3) (c) Visually check the spark plug. If the electrode is dry ... OK If the electrode is wet ... Proceed to step 4 (d) Reinstall the spark plug. (See step 7 on page IG–29) 3. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the spark plug. IG–29 IGNITION SYSTEM – (5S–FE Except California) 4. VISUALLY INSPECT SPARK PLUGS Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: PK20R 11 for N D BKR6EP11 for NGK 5. INSPECT ELECTRODE GAP Maximum electrode gap: 1.3 mm (0.051 in.) If the gap is greater than maximum, replace the spark plug. Correct electrode gap of new spark plug: 1.1 mm (0.043 in.) NOTICE: If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on the used plug. 6. CLEAN SPARK PLUGS If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/cm2, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. 7. INSTALL SPARK PLUGS Using a 16 mm plug wrench, install the spark plug. Torque: 18 N–m (180 kgf–cm, 13 ft–lbf) 8. RECONNECT HIGH–TENSION CORDS TO SPARK PLUGS IG–30 IGNITION SYSTEM – (5S–FE Except California) DISTRIBUTOR INSPECTION NOTICE: ’Cold’ and ’Hot’ in the following sentences ex– press the temperature of the coils themselves. ’Cold’ is from–10
C (14
F) to 50
C (122
F) and ’Hot’ is from 50
C (122
F) to 100
C (212
F). 1. 2. 3. 4. DISCONNECT DISTRIBUTOR CONNECTORS REMOVE DISTRIBUTOR CAP REMOVE ROTOR REMOVE IGNITION COIL DUST COVER Ignition Coil 5. INSPECT PRIMARY COIL RESISTANCE Using an ohmmeter, measure the resistance between– the positive (+) and negative (–) terminals. Primary coil resistance (Cold): 0.38–0.550 Primary coil resistance (Hot): 0.45–0.650 If the resistance is not as specified, replace the igni– tion coil. 6. INSPECT SECONDARY COIL RESISTANCE Using an ohmmeter, measure the resistance between positive (+) and high–tension terminals. Secondary coil resistance (Cold): 9.0–15.4 k
Secondary coil resistance (Hot): 11.4–18.1 k
If the resistance is not as specified, replace the igni– tion coil. Distributor 7. INSPECT AIR GAP Using a thickness gauge, measure the air gap between the signal rotor and pickup coil projection. Air gap: 0.2–0.4 mm (0.008–0.018 in.) If the air gap is not as specified, replace the distributor housing assembly. IG–31 IGNITION SYSTEM – (5S–FE Except California) 8. INSPECT SIGNAL GENERATOR (PICKUP COIL) RESISTANCE Using an ohmmeter, measure the resistance between the terminals (G
and G, NE
and NE). Pickup coil resistance (Cold): G
and G 185–2750 NE
and NE 370–5500 Pickup coil resistance (Hot): G
and G 240–3250 NE
and NE 475–6500 If the resestance is not as specified, replace the dis– tributor housing assmebly. 9. REINSTALL IGNITION COIL DUST COVER 10. REINSTALL ROTOR 11. REINSTALL DISTRIBUTOR CAP 12. RECONNECT DISTRIBUTOR CONNECTORS IGNITER INSPECTION (See Spark Test procedure on page IG–26) IG–32 IGNITION SYSTEM – (5S–FE Except California) DISTRIBUTOR COMPONENTS FOR REMOVAL AND INSTALLATION DISTRIBUTOR REMOVAL 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch (: turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. DISCONNECT ACCELERATOR CABLE FROM THROTTLE LINKAGE IG–33 IGNITION SYSTEM – (5S–FE Except California) 3. REMOVE AIR CLEANER CAP, RESONATOR AND AIR CLEANER HOSE (a) Disconnect the intake air temperature sensor connec– tor. (b) Loosen the air cleaner hose clamp bolt. (c) Disconnect the 4 air cleaner cap clips. (d) Disconnect the air cleaner hose from the throttle body, and remove the air cleaner cap together with the resonator and air cleaner hose. 4. DISCONNECT DISTRIBUTOR CONNECTORS 5. DISCONNECT HIGH–TENSION CORDS FROM SPARK PLUGS (a) Disconnect the 4 high–tension cords from the spark plugs. (b) Disconnect the high–tension cords from the clamp on the cylinder head cover. 6. REMOVE DISTRIBUTOR (a) Remove the 2 hold–down bolts, and pull out the distributor. (b) Remove the 0–ring from the distributor housing. IG–34 IGNITION SYSTEM – (5S–FE Except California) COMPONENTS FOR DISASSEMBLY AND ASSEMBLY DISTRIBUTOR DISASSEMBLY 1. REMOVE DISTRIBUTOR CAP WITHOUT DISCONNECTING HIGH–TENSION CORDS 2. REMOVE ROTOR 3. REMOVE IGNITION COIL DUST COVER 4. REMOVE IGNITION COIL (a) Remove the 2 nuts, and disconnect the 3 wires from the ignition coil terminals. IG–35 IGNITION SYSTEM – (5S–FE Except California) (b) Remove the 4 screws and ignition coil. B. REMOVE DISTRIBUTOR WIRE Remove the distributor wire from the distributor hous– ing. 6. REMOVE CONDENSER Remove the screw and condenser. DISTRIBUTOR INSPECTION INSPECT SHAFT Turn the shaft and check that it is not rough or worn. If it feels rough or worn, replace the distributor hous– ing assembly. DISTRIBUTOR ASSEMBLY (See Components for Disassembly and Assembly) 1. INSTALL CONDENSER Install the condenser with the screw. IG–36 IGNITION SYSTEM – (5S–FE Except California) 2. INSTALL DISTRIBUTOR WIRE Install the grommet of the wire to the distributor housing. 3. INSTALL IGNITION COIL (a) Remove any old packing (FIPG) material. (b) Apply seal packing to the ignition coil installing sur– face of the housing as shown in the illustration. Seal packing: Part No. 08826–00080 or equivalent (c) Install the ignition coil with the 4 screws. (d) Connect the 3 wires to the ignition coil terminals with the 2 nuts. NOTICE: • When connecting the wires to the ignition coil. insert both properly into their grooves found on the side of the Ignition coil. • Be sure the wires do not contact with signal rotor or distributor housing. IG–37 IGNITION SYSTEM – (5S–FE Except California) 4. INSTALL IGNITION COIL DUST COVER 5. INSTALL ROTOR 6. INSTALL DISTRIBUTOR CAP AND HIGH–TENSION CORDS DISTRIBUTOR INSTALLATION (See Components for Disassembly and Assembly) 1. SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft clockwise, and position the slit of the intake camshaft as shown in the illustration. 2. INSTALL DISTRIBUTOR (a) Install a new O–ring to the housing. (b) Apply a light coat of engine oil on the 0–ring. (c) Align the cutout of the coupling with the line of the housing. (d) Insert the distributor, aligning the center of the flange with that of bolt hole on the cylinder head. (e) Lightly tighten the 2 hold–down bolts. (f) Connect the high–tension cords to the clamp on the cylinder head cover. . IG–38 IGNITION SYSTEM – (5S–FE Except California) 3. CONNECT HIGH–TENSION CORDS TO SPARK PLUGS Firing order: 1–3–4–2 4. CONNECT DISTRIBUTOR CONNECTORS 5. INSTALL AIR CLEANER CAP, RESONATOR AND AIR CLEANER HOSE (a) Connect the air cleaner hose to the throttle body. (b) Install the air cleaner cap together with the resonator and air cleaner hose. (c) Connect the intake air temperature sensor connector. 6. CONNECT AND ADJUST ACCELERATOR CABLE 7. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 8. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 9. CONNECT TACHOMETER Connect the test probe of a tachometer to terminal IG E) of the data link connector 1. NOTICE: • NEVER allow the tachometer terminal to touch ground as it could result in damage to the igniter and/or ignition coil. • As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of yours before use. 10. ADJUST IGNITION TIMING (a) Using SST, connect terminals TE 1 and E 1 of the data link connector 1. SST 09843–18020 HINT: After engine speed is kept at 1,000–1,300 rpm for 5 seconds, check that it returns to idle speed. IG–39 IGNITION SYSTEM – (5S–FE Except California) (b) Using a timing light, check the ignition timing. Ignition timing: 10
BTDC 0 Idle (Transmission In neutral position) (c) Loosen the 2 hold–down bolts, and adjust by turning the distributor. (d) Tighten the hold–down bolts, and recheck the igni– tion timing. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) (e) Remove the SST. SST 09843–18020 11. FURTHER CHECK IGNITION TIMING Ignition timing: 0–10
BTDC 0 idle (Transmission In neutral position) HINT: The timing mark moves in a range between 0
and 10
. 12. DISCONNECT TACHOMETER AND TIMING LIGHT FROM ENGINE IG–40 IGNITION SYSTEM SERVICE SPECIFICATIONS SERVICE DATA Ignition timing w/ Terminals TE1 end E1 connected of DLC1 Firing order High–tension cord Resistance Spark plug Recommended spark plug Correct electrode gap Ignition coil Primary coil resistance Secondary coil resistance Distributor Air gap Pickup coil resistance TORQUE SPECIFICATIONS Part tightened Spark plug x Cylinder heed Distributor x Cylinder head – (5S–FE Except California) IG–41 IGNITION SYSTEM – (1MZ–FE) (1 MZ–FE) DESCRIPTION The engine control module (ECM) is programmed with data for optimum ignition timing under all operating conditions. Using data provided by sensors which monitor various engine functions (RPM, intake air volume, engine temperature, etc.), the ECM triggers the spark at precisely the right instant. The ECM monitors the engine condition by signals from each sensor, calculates the ignition timing and sends an ignition signal to the igniter. High voltage from the ignition is distributed to each spark plug in the appropriate order to generate a spark between the electrodes, which ignites the air–fuel mixture. IGNITER The igniter interrupts the primary current with the ignition signal (lGT signal) from the ECM and generates sparks at the spark plug. Also, as a fail–safe measure, when ignition occurs an ignition confirmation signal (lGF signal) is sent to the ECM. IGNITION COILS The ignition coil uses a closed core coil with the primary coil wrapped around the core and the secondary coil wrapped around the primary coil. This allows the generation of a high voltage sufficient to cause a spark to jump across the spark plug gap. CAMSHAFT POSITION SENSOR The camshaft position sensor detect the camshaft position. CRANKSHAFT POSITION SENSOR The crankshaft position sensor detect the crankshaft position. IG–42 IGNITION SYSTEM – (1MZ–FE) PRECAUTION 1. Do not leave the ignition switch on for more than 10 minutes if the engine does not start. 2. With a tachometer connected to the system, con– nect the tester probe of the tachometer to terminal IG
of the DLC 1. 3. With a timing tight connected to the system, con– nect the timing light pickup clip to the green lead wire for the No.4 ignition coil. 4. As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of your unit before use. 5. Never allow the tachometer terminals to touch ground as it could result in damage to the igniter and/or ignition coil. 6. Do not disconnect the battery while the engine is running. 7. Check that the igniter is properly grounded to the body. IG–43 IGNITION SYSTEM – (1MZ–FE) SYSTEM CIRCUIT OPERATION To maintain the most appropriate ignition timing, the ECM sends a control signal so that the igniter is pass the current to the ignition coils and the spark plugs produce a spark. IG–44 IGNITION SYSTEM – (1MZ–FE) PREPARATION RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester Set 09200–00010 Engine Adjust Kit EQUIPMENT Megger insulation resistance meter Spark plug cleaner Thermometer Timing light Spark plug IG–45 IGNITION SYSTEM – (1MZ–FE) ON–VEHICLE INSPECTION SPARK TEST CHECK THAT SPARK OCCURS (a) Remove the ignition coil. (See steps 1 to 3 on page IG–50) (b) Remove the spark plug. (See step 3 on page IG–47) (c) Install the spark plug to the ignition coil, and connect the ignition coil connecter. (d) Ground the spark plug. (e) Check if spark occurs while engine is being cranked. HINT: To prevent gasoline from being injected from injectors during this test, crank the engine for no more than 1–2 seconds at time. If the spark does not occur, perform the test as fol– lows: SPARK TEST CHECK CONNECTION OF IGNITION COIL AND IGNITER CHECK POWER SUPPLY TO IGNITION COIL AND IGNITER 1. Turn ignitioin switch ON. 2. Check that there is battery voltage at Ignition coil positive (+) terminal. CHECK RESISTANCE OF IGNITION COIL (See page IG–48) Resistance: Primary Cold : 0.54–0.84II, Hot : 0.68–0.98 n CHECK RESISTANCE OF CAMSHAFT POSITION SENSOR (See page IG–49) Resistance: Cold : 835–1,4000, Hot : 1,060–1,6450 CHECK RESISTANCE OF CRANKSHAFT POSITION SENSOR (See page IG–54) Resistance: Cold : 1,630–2,7400, Hot : 2,065–3,2250 CHECK IGT SIGNAL FROM ECM (See page EG–550) TRY ANOTHER IGNITER BAD BAD BAD BAD BAD BAD Connect securely. Check wiring between ignition switch to ignition coil and igniter. Replace the ignition coil. Replace the camshaft position sensor. Replace the crankshaft position sensor. Check wiring between ECM, and igniter, and then try another ECM. IG–46 IGNITION SYSTEM – (1MZ–FE) (f) Reinstall the spark plug. (See step 7 on page IG–47) (g) Reinstall the ignition coil. (See steps 1 to 3 on page IG–51) SPARK PLUGS INSPECTION NOTICE: • Never use a wire brush for cleaning. • Never attempt to adjust the electrode gap on a used spark plug. • Spark plugs should be replaced every 100,000 km (60,000 miles). 1. REMOVE IGNITION COILS (See steps 1 to 3 on page IG–b0) 2. INSPECT ELECTRODE Using a megger (insulation resistance meter), measure the insulation resistance. Standard correct Insulation resistance: 10 M
or more If the resistance is less than specified, proceed to step 4. HINT: If a megger is not available, the following simple method of inspection provides fairly accurate results. Simple Method: (a) Quickly race the engine to 4,000 rpm 5 times. (b) Remove the spark plug. (See step 3) (c) Visually check the spark plug. If the electrode is dry ... OK If the electrode is wet ... Proceed to step 4 (d) Reinstall the spark plug. (See step 7) IG–47 IGNITION SYSTEM – (1MZ–FE) 3. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the ^ spark plugs from the RH and LH cylinder heads. 4. VISUALLY INSPECT SPARK PLUGS Check the spark plug for thread damage and insulator damage. If abnormal, replace the spark plug. Recommended spark plug: PK20R11 for ND BKR6EP–11 for NGK 5. INSPECT ELECTRODE GAP Maximum electrode gap for used spark plug: 1.3 mm (0.051 in.) If the gap is greater than maximum, replace the spark plug. Correct electrode gap for now spark plug: 1.1 mm (0.043 in.) NOTICE: If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on the used plug. 6. CLEAN SPARK PLUGS If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/cm2, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner. 7. REINSTALL SPARK PLUGS Using a 16 mm plug wrench, install the6 spark plugs to the RH and LH cylinder heads. Torque: 18 N–m (180 kgf–cm. 13 ft–lbf) 8. REINSTALL IGNITION COILS (See steps 1 to 3 on page IG–51) IG–48 IGNITION SYSTEM – (1MZ–FE) IGNITION COIL INSPECTION NOTICE: ’Cold’ and ’Hot’ in the following sentences ex– press the temperature of the coils themselves. “Cold” is from–10
C (14
F) to 50
C (1122* F) and ’Hot’ is from 60
C (122
F) to 100
C (212
F). 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE V–BANK COVER Using a 5 mm hexagon wrench, remove the 2 cap nuts and V–bank cover. 3. DISCONNECT IGNITION COIL CONNECTORS 4. INSPECT PRIMARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the positive (+) and negative (–) terminals. Primary coil resistance (Cold): 0.54–0.84
Primary coil resistance (Hot): 0.68–0.980 If the resistance is not as specified, replace the igni– tion coil. (See page I G–50) IG–49 IGNITION SYSTEM – (1MZ–FE) 5. RECONNECT IGNITION COIL CONNECTORS 6. REINSTALL V–BANK COVER Using a 5 mm hexagon wrench, install the V–bank cover with the 2 cap nuts. HINT: For fixing the V–bank cover, push on the cover until sense of “click” is felt. 7. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY CAMSHAFT POSITION SENSOR INSPECTION NOTICE: ’Cold’ and ’Hot’ in the following sentences ex– press the temperature of the sensors themselves. ’Cold’ Is from–10
C (14
F) to 50
C (122
F) and “Hot’ is from 50
C 0 22
F) to 100
C (212
P). 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the Ignition switch Is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. DISCONNECT CAMSHAFT POSITION SENSOR CONNECTOR 3. INSPECT CAMSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (Cold): 835–1,4000 Resistance (Hot): 1,060–1,645 0 If the resistance is not as specified, replace the cam– shaft position sensor. (See page IG–52) 4. RECONNECT CAMSHAFT POSITION SENSOR CONNECTOR 5. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY IGNITER INSPECTION (See procedure Spark Test on page IG–46) IG–50 IGNITION SYSTEM – (1MZ–FE) IGNITION COIL IGNITION COILS REMOVAL 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the Ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE V–BANK COVER Using a 5 mm hexagon wrench, remove the 2 cap nuts and V–bank cover. 3. REMOVE IGNITION COILS (a) Disconnect the 6 connectors from the RH and LH cylinder heads. (b) Remove the 8 bolts and6 ignition coils from the RH and LH cylinder heads. HINT: Arrange the ignition coils in correct order. IG–51 IGNITION SYSTEM – (1MZ–FE) IGNITION COIL INSTALLATION 1. INSTALL IGNITION COILS (a) Install the6 ignition coils to the RH and LH cylinder heads with the ^ bolts. Torque: 8 N–m (80 kgf–cm. 89 in.Ibf) (b) Connect the 6 ignition coil connectors. 2. INSTALL V–BANK COVER Using a 5 mm hexagon wrench, install the V–bank cover with the 2 cap nuts. HINT: For fixing the V–bank cover, push on the cover until sense of “click” is felt. 3. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY IG–52 IGNITION SYSTEM – (1MZ–FE) CAMSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR REMOVAL 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the “LOCK” position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the 2 bolts and camshaft position sensor. CAMSHAFT POSITION SENSOR INSTALLATION 1. INSTALL CRANKSHAFT POSITION SENSOR Torque: 8 N–m (80 kgf–cm, 69 in.ibf) 2. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY IG–53 IGNITION SYSTEM – (1MZ–FE) CRANKSHAFT POSITION SENSOR COMPONENTS FOR REMOVAL AND INSTALLATION CRANKSHAFT POSITION SENSOR REMOVAL (See Components for Removal and Installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the Ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE RH ENGINE UNDER COVER 3. REMOVE RH FENDER APRON SEAL IG–54 IGNITION SYSTEM – (1MZ–FE) 4. DISCONNECT ENGINE WIRE Remove the 3 nuts and disconnect the engine wire. 5. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the bolt and disconnect the crankshaft posi– tion sensor. (b) Disconnect the crankshaft position sensor conecter. CRANKSHAFT POSITION SENSOR INSPECTION NOTICE: ’Cold’ and ’Hot’ in the following sentences ex– press the temperature of the sensors themselves. ’Cold’ is from–10
C (14
F) to 50
C (122
F) and ’Hot’ is from 50
C (122
F) to 100
C (212
F). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (Cold): 1,630–2,740 0 Resistance (Hot): 2,060–3,225 0 If the resistance is not as specified, replace the crank shaft position sensor. IG–55 IGNITION SYSTEM – (1MZ–FE) CRANKSHAFT POSITION SENSOR INSTALLATION (See Components for Removal and Installation) 1. INSTALL CRANKSHAFT POSITION SENSOR Torque: 8 N–m (80 kgf–cm, 69 in.lbf) 2. CONNECT ENGINE WIRE 3. INSTALL RH FENDER APRON SEAL 4. INSTALL RH ENGINE UNDER COVER 6. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY IG–56 IGNITION SYSTEM SERVICE SPECIFICATIONS SERVICE DATA Ignition timing w/ Terminals TE1 and E1 connected of DLC1 Firing order Spark plug Recommended spark plug Correct electrode gap for new plug Maximum electrode gap for used plug Ignition coil Primary coil resistance Camshaft position sensor Resistance Crankshaft position sensor Resistance TORQUE SPECIFICATIONS Part tightened Spark plug x Cylinder heed Ignition coil x Cylinder head Camshaft position sensor x Cylinder head Crankshaft position sensor x Oil pump – (1MZ–FE) IN–1 INTRODUCTION – INTRODUCTION IN–2 INTRODUCTION – HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL INDEX An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. GENERAL DESCRIPTION At the beginning of each section, a General Description is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. 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 –19. Be sure to read this before performing troubleshooting. PREPARATION Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: IN–3 INTRODUCTION – HOW TO USE THIS 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. Example: This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to. 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 are also found at the end of each section, for quick reference. IN–4 INTRODUCTION – HOW TO USE THIS MANUAL 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. S1 UNIT 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 kgf–cm, 22 ft–lbf) IN–5 INTRODUCTION – IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle identification number plate and certification label. A. Vehicle Identification Number Plate B. Certification Label ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block as shown. IN–6 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS GENERAL REPAIR INSTRUCTIONS 1. Use fender, seat and floor covers to keep the vehicle clean and prevent damage. 2. During disassembly, keep parts in the appropriate order to facilitate reassernbly. 3. Observe the following: CAUTION: Work must be started after approx 90 sec– onds from the time the ignition switch is turned to the “LOOK” position and the negative (–) terminal cable is disconnected from the battery (See page RS–2). (a) Before performing electrical work, disconnect the negative cable from the battery terminal. (b) If it is necessary to disconnect the battery for inspection or repair, always disconnect the cable from the negative (–) terminal which is grounded to the vehicle body. (c) To prevent damage to the battery terminal post, loosen the terminal nut and raise the cable strai– ght up without twisting or prying it. (d) Clean the battery terminal posts and cable termi– nals with a clean shop rag. Do not scrape them with a file or other abrasive objects. (e) Install the cable terminal to the battery post with the nut loose, and tighten the nut after installa– tion. Do not use a hammer to tap the terminal onto the post. (f) Be sure the cover for the positive (+) terminal is properly in place. 4. Check hose and wiring connectors to make sure that they are secure and correct. 5. Non – reusable parts (a) Always replace cotter pins, gaskets, 0–rings and oil seals etc. with new ones. (b) Non–reusable parts are indicated in the compo– nent illustrations by the “” symbol. 6. Precoated parts Precoated parts are bolts and nuts, etc. that are coated with a seal lock adhesive at the factory. (a) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. IN–7 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS (b) 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. (c) Precoated parts are indicated in the component illustrations by the “
” symbol. 7. When necessary, use a sealer on gaskets to prevent leaks. 8. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. 9. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work proce– dure. A list of SST and SSM can be found in the preparation part at the front of each section in this manual. 10. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating. Illustration Symbol Part Name Abbreviation FUSE FUSE MEDIUM CURRENT FUSE M–FUSE HIGH CURRENT FUSE H–FUSE FUSIBLE LINK CIRCUIT BREAKER IN–8 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS 11. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See page IN–37) (a) If the vehicle is to be jacked up only at the front or rear end, be sure to block the wheels at the opposite end in order to ensure safety. (b) After the vehicle is jacked up, be sure to support it on stands. 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. 12. Observe the following precautions to avoid damage to the parts: (a) Do not open the cover or case of the ECU, ECM, PCM or TCM unless absolutely necessary. (If the IC terminals are touched, the IC may be destr– oyed by static electricity.) (b) To disconnect vacuum hoses, pull on the end, not the middle of the hose. (c) To pull apart electrical connectors, pull on the connector itself, not the wires. (d) Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. (e) When steam cleaning an engine, protect the dis– tributor, air filter, and VCV from water. (f) Never use an impact wrench to remove or install temperature switches or temperature sensors. (g) When checking continuity at the wire connector, insert the tester probe carefully to prevent termi– nals from bending. (h) When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step–down adapter instead. Once the hose has been stretched, it may leak. 13. Tag hoses before disconnecting them: (a) When disconnecting vacuum hoses, use tags to identify how they should be reconnected. (b) After completing a job, double check that the vacuum hoses are properly connected. A label under the hood shows the proper layout. IN–9 INTRODUCTION – GENERAL REPAIR INSTRUCTIONS 14. Unless otherwise stated, all resistance is measured at an ambient temperature of 20C (68F). Because the resistance may be outside specifications if measured at high temperatures immediately after the vehicle has been running, measurements should be made when the engine has cooled down. IN–10 INTRODUCTION – FOR VEHICLES WITH DATA LINK CONNECTOR 2 (DLC2) FOR VEHICLES WITH DATA LINK CONNECTOR 2 (DLC2) The DLC2 is provided inside the cabin (located under the left side instrument panel) as a connector exclu– sively for diagnosis of data from the engine, automatic transmission, ABS, A/C, Airbag and Cruise Control System to improve serviceability. The DLC1 inside the engine compartment is used for engine adjust– ment. Connecting the following terminals of the DLC2 to terminal E, selects the diagnosis mode shown. NOTICE: Never make a mistake with the terminal connec– tion position as this will cause a malfunction. Terminal TE2 and TE1 System Engine and automatic transmission (Normal mode) Engine and automatic transmission (Test mode) ABS, A/C, Airbag and Cruise Control System Automatic transmission Refer to the respective system for the inspection method. HINT: By connecting the DLC2 up to a monitor specif– ically designed for use with the DLC2, the diagnosis result for each system can be read easily. IN–11 INTRODUCTION – PRECAUTION PRECAUTION FOR VEHICLES EQUIPPED WITH SRS AIRBAG The 1994 CAMRY specifications is equipped with an SRS (Supplemental Restraint System) airbag. Failure to carry out service operations in the correct sequence could cause the airbag system to unexpect– edly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the airbag system, it is possible the airbag may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replace– ment), be sure to read the following items carefully, then follow the correct procedure described in this manual. Locations of Airbag Components IN–12 INTRODUCTION – PRECAUTION 1. Malfunction symptoms of the airbag system are diffi– cult to confirm, so the diagnostic codes become the most important source of information when trouble– shooting. When troubleshooting the airbag system, always inspect the diagnostic codes before dis– connecting the battery (See page RS–55). 2. Work must be started after approx 90 seconds from the time the Ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is dis– connected from the battery. (The airbag system is equipped with a back–up power source so that if work is started within 90 seconds of disconnecting the negative (–) terminal cable of the battery, the airbag may be deployed.) When the negative (–) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by each memory system. Then when work is finished, reset the clock and audio systems as before. To avoid erasing the memory of each memory system, never use a back–up power supply from outside the vehicle. 3. Even in cases of a minor collision where the airbag does not deploy, the front airbag sensors , passenger ’s airbag assembly and the steering wheel pad should be inspected (See page RS–17, 29, 43). 4. Never use airbag parts from another vehicle. When replacing parts, replace them with new parts. 5. Before repairs, remove the airbag sensors if shocks are likely to be applied to the sensors during repairs. 6. The center airbag sensor assembly contains mercury. After performing replacement, do not destroy the old part. When scrapping the vehicle or replacing the center airbag sensor assembly itself, remove the center airbag sensor assembly and dispose of it as toxic waste. 7. Never disassemble and repair the front airbag sensors, center airbag sensor assembly or steering wheel pad in order to reuse it. 8. If the front airbag sensors, center airbag sensor as– sembly or steering wheel pad have been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. 9. Do not expose the front airbag sensors, center airbag sensor assembly or steering wheel pad directly to hot air or flames. 10. Use a volt/ohmmeter with high impedance (10 k
/V minimum) for troubleshooting of the electrical circuit. IN–13 INTRODUCTION – PRECAUTION 11. Information labels are attached to the periphery of the airbag components. Follow the notices. 12. After work on the airbag system is completed, per– form the airbag warning light check (See page RS– 55). Front Airbag Sensor 1. Never reuse the front airbag sensors involved in a collision when the airbag has deployed. (Replace both left and right airbag sensors.) 2. Install the front airbag sensor with the arrow on the sensor facing toward the front of the vehicle. 3. The front airbag sensor set bolts have been anti –rust treated. When the sensor is removed, always replace the set bolts with new ones. 4. The front airbag sensor is equipped with an electrical connection check mechanism. Be sure to lock this mechanism securely when connecting the connector. If the connector is not securely locked, a malfunction code will be detected by the diagnosis system (See page RS–13). Spiral Cable (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position; otherwise cable disconnection and other tro– ubles may result. Refer to page RS–19 concerning correct steering wheel installation. IN–14 INTRODUCTION – PRECAUTION Steering Wheel Pad (with Airbag) 1. When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. 1n this case, the twin –lock type connector lock lever should be in the locked state and care should be taken to place it so the connector will not be damaged. And do not store a steering wheel pad on top of another one. (Storing the pad with its metallic surface up may lead to a serious accident if the airbag inflates for some reason.) 2. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) 3. Grease should not be applied to the steering wheel pad and the pad should not be cleaned with deter– gents of any kind. 4. Store the steering wheel pad where the ambient tem– perature remains below 93
C (200
F), without high humidity and away from electrical noise. 5. When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the steering column near the combination switch connec– tor before starting work. 6. When disposing of a vehicle or the steering wheel pad alone, the airbag should be deployed using an SST before disposal (See page RS–22). Perform the operation in a place away from electrical noise. IN–15 INTRODUCTION – PRECAUTION Front Passenger Airbag Assembly 1. Always store a removed or new front passenger airbag assembly with the airbag door facing up. Storing the airbag assembly with the airbag door facing down could cause a serious accident if the airbag inflates. 2. Never measure the resistance of the airbag squib. (This may cause the airbag deploy, which is very dangerous.) 3. Grease should not be applied to the front passenger airbag assembly and the airbag door should not be cleaned with detergents of any kind. 4. Store the airbag assembly where the ambient temper– ature remains below 93
C (200
F), without high hu– midity and away from electrical noise. 5. When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed on the glove compartment finish plate at the left side of the glove compartment before starting work. 6. When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using an SST before disposal (See page RS–35). Perform the operation in a safe place away from electrical noise. IN–16 INTRODUCTION – PRECAUTION Center Airbag Sensor Assembly The connector to the center airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. If the connector is connected or disconnected while the center airbag sensor as– sembly is not mounted to the floor, it could cause undesired ignition of the airbag system. Wire Harness and Connector The airbag system’s wire harness is integrated with the cowl wire harness assembly. The wires for the airbag wire harness are encased in a yellow cor– rugated tube. All the connectors for the system are also a standard yellow color. If the airbag system wire harness becomes disconnected or the connector bec– omes broken due to an accident, etc., repair or replace it as shown on page RS–50. IN–17 INTRODUCTION – PRECAUTION FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: If large amounts of unburned gasoline flow into the converter, It may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer. 1. Use only unleaded gasoline. 2. Avoid prolonged idling. Avoid running the engine at idle speed for more than 20 minutes. 3. Avoid spark jump test. (a) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (b) While testing, never race the engine. 4. Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible. 5. 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. 6. Avoid coasting with ignition turned off and prolonged braking. 7. Do not dispose of used catalyst along with parts contaminated with gasoline or oil. FOR VEHICLES WITH AN AUDIO SYSTEM WITH BUILT–IN ANTI–THEFT SYSTEM Audio System displaying the sign ”ANTI –THEFT SYSTEM” shown on the left has a built–in anti–theft system which makes the audio system soundless if stolen. If the power source for the audio system is cut even once, the anti–theft system operates so that even if the power source is reconnected, the audio system will not produce any sound unless the ID number selected by the customer is input again. Accordingly, when performing repairs on vehicles equipped with this system, before disconnecting the battery termi– nals or removing the audio system the customer should be asked for the ID number so that the techni– cian can input the ID number afterwards, or else a request made to the customer to input the ID number. For the method to input the ID number or cancel the anti–theft system, refer to the Owner’s Manual. IN–18 INTRODUCTION – PRECAUTION IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as two–way radios and cellular telephones, ob– serve the following precautions. (1) Install the antenna as far as possible away from the ECM, ECU and sensors of the vehicle’s electronic system. (2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECM, ECU and sensors of the vehicle’s electronics systems. For details about ECM, ECU and sensors locations, refer to the section on the applica– ble component. (3) Do not wind the antenna feeder together with the other wiring. As much as possible, also avoid running the antenna feeder parallel with other wire harnesses. (4) Confirm that the antenna and feeder are correctly adjusted. (5) Do not install powerful mobile communications system. INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS IN–19 HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS A large number of ECU controlled systems are used in the TOYOTA CAMRY*. In general, the ECU controlled system is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits 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. Thismanual is designed through emphasis of the above standpoint to help service technicians perform accurate and effective troubleshooting, and is compiled for the following major ECU controlled systems: Repair Manual Vol. 1 Vol. 2 System Page 5S–FE Engine EG–291 1MZ–FE Engine EG–394 A140E Automatic Transaxle AX–39 A541E Automatic Transaxle AX–49 Anti–Lock Brake BR–90 Supplemental Restraint System RS–53 Cruise Control BE–161 The troubleshooting procedure and how to make use of it are described on the following pages. IN–20 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic proce– dure is shown. Details are provided in each section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit. Vehicle Brought to Workshop Customer Problem Analysis Ask the customer about the conditions and the environment when the problem occurred. Symptom Confirmation and Diagnostic Trouble Code Check Symptom Simulation Diagnostic Trouble Code Chart Matrix Chart of Problem Symptoms Circuit Inspection or Parts Inspection Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes. (When the problem symptoms do not appear dur– ing confirmation, use the symptom simulation method described later on.) 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 code chart or the matrix chart of problem symptoms. Check and repair the affected system or part in accordance with the instructions in Step 6 . Repair Confirmation Test End After completing repairs, confirm that the problem has been eliminated. (If the problem is not reproduced, perform the con– firmation test under the same conditions and in the same environment as when it occurred for the first time.) INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS IN–21 1 CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgement. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred. Important Points 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 the troubleshooting section for each system for your use. Important Points in the Customer Problem Analysis • What Vehicle model, system name • When Date, time, occurrence frequency • Where Road conditions • Under what conditions? Running conditions, driving conditions, weather conditions • How did it happen? Problem symptoms (Sample) Engine control system check sheet. IN–22 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS 2 SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the TOYOTA CAIVIRY fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory atthetime of occurrence, to be output bythetechnician 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 TOYOTA CAMRY System Diagnostic Trouble Code Check Input Signal Check (Sensor Check) Other Diagnosis Function 5S–FE Engine Diagnostic Test Mode 1MZ–FE A140E Automatic Transaxle Diagnostic Test Mode A540E Anti–Lock Brake Supplemental Restraint System Cruise Control In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diagnostic trouble code is still occurring 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 after 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 correct order and perform the diagnostic trouble code check. DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE Diagnostic Trouble Code Check (Make a note of and then clear) Diagnostic Trouble Code Display Confirmation of Symptoms Problem symptoms exist Diagnostic Trouble Code Check Same diagnostic trouble code is displayed Problem is still occurring in the diagnostic circuit. Normal code is displayed The problem is still occurring in a place other than in the diagnostic circuit. (The diagnostic trouble code displayed first is either for a past problem or it is a secondary problem.) No problem symptoms exist Normal Code Display Problem Condition The problem occurred, in the diagnostic circuit in the past. Problem symptoms exist Normal code is displayed The problem is still occurring in a place other than in the diagnostic circuit. No problem symptoms exist Normal code is displayed The problem occurred in a place other than in the diagnostic circuit in the past. INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS IN–23 Taking into account the above points, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnostic 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. Diagnostic trouble code check Making a note of and clearing of the diagnostic trouble codes displayed Symptom confirmation No problem symptoms Problem symptoms exist exist Simulation test using the symptom simulation methods Diagnostic trouble code check • Diagnostic trouble code displayed • Problem symptoms exist • Normal code displayed • Problem symptoms exist • Normal code displayed • No problem symptoms exist System Normal Troubleshooting of problem indicated by diagnostic trouble code Troubleshooting of each problem symptom If a diagnostic trouble code was displayed in the initial diagnostic trouble code check, it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past. Therefore, check the wire harness and connectors (See page IN–31 ) 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, a thorough customer problem analysis must be carried out, then¿simulate the same or similar conditions and environment in which the problem occurred in the customer’s vehicle. No matter now 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 guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem 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) are likely causes for problems which are difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external 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 circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the matrix chart of problem symptoms for each system to narrow down the possible causes of the symptom. VIBRATION METHOD: When vibration seems to be the major cause. CONNECTORS Slightly shake the connector vertically and horizontally. WIRE HARNESS Slightly shake the wire harness vertically and horizon– tally. The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thoroughly. PARTS AND SENSORS Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check if the malfunction occurs. HINT: Applying strong vibration to relays may result in open relays. INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS HEAT METHOD: When the problem 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 see if the malfunction occurs. NOTICE: (1) Do not heat to more than 60C (140F). (Temperature limit that no damage is done to the component). (2) Do not apply heat directly to parts in the ECU. When the malfunction seems to occur on a rainy day WATER SPRINKLING METHOD: or in a high–humidity condition. Sprinkle water onto the vehicle and check to see if the malfunction occurs. NOTICE: (1) Never sprinkle water directly into the engine compartment, but indirectly change the temperature and humidity by applying water spray onto the radiator front surface. (2) Never apply water directly onto the electronic com– ponents. (Service hint) If a vehicle is subject to water leakage, the leaked water may contaminate the ECU. When testing a vehicle with a water leakage problem, special caution must be used. OTHER: When a malfunction seems to occur when electrical load is excessive. Turn on all electrical loads including the heater blower, head lights, rear window defogger, etc. and check to see if the malfunction occurs. IN–25 IN–26 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS 4 DIAGNOSTIC TROUBLE CODE CHART The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example. • DTC No. • Detection Item Indicates the diagnostic trouble code. Indicates the system of the problem or contents of the problem. • Diagnostic Trouble Code Detecting Condition Indicates the diagnostic trouble code set parameter. • Trouble Area Indicates the suspect area of the problem . • Page or Instructions Indicates the page where the inspection procedure for each circuit is to be found, or gives instructions for checking and repairs. INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS IN–27 5 MATRIX CHART OF PROBLEM SYMPTOMS The suspect circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshooting 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, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. • Page Indicates the page where the flow chart for each circuit is located. • Problem Symptom • Circuit or Part Name Indicates the circuit or part which needs to be checked. • Circuit Inspection, Inspection Order Indicates the circuit which needs to be checked for each problem symptom. Check in the order indicated by the numbers. IN–28 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 cir– cuit and its component parts are explained. • Indicates the diagnostic trouble code, diagnostic trouble code set parameter and suspect area of the problem. • Diagnostic Chart The troubleshooting procedure for the circuit is shown in a flow chart. Use it to determine if the circuit is normal or abnormal, and, if it is abnormal, use it to determine whether the problem is located in the sen– sors, actuators, wire harness or ECU. For details of each in– spection, the page number of the related ”Inspection Proce– dure” is included. WIRING DIAGRAM • Wiring Diagram This shows a wiring diagram of the circuit. Use thi: diagram together with the location of connector to thoroughly understand the circuit. INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS IN–29 Location of Connectors in Engine Compartment • Location of connectors This diagram shows the wire harnesses and connectors used in one system. The connector shows the harness side connector, so when checking the part side connector (sensor, actuator, etc.), be careful not to mistake the terminal positions. IN–30 INTRODUCTION • Indicates the position of the ignition switch during the check. HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS • Inspection Procedure This shows the inspection procedure on the diagnostic chart in detail. Ul Check voltage between terminals VTA and E2 of ECM. Check and replace ECM (See page IN–36). Preparation Check Check • Indicates the place to check the voltage or resistance. • Indicates the connector position to be checked, from the front or back side. Check from the connector back side. (with harness) Check from the connector front side (without harness) In this case, care must be taken not to bend the terminals. • Indicates the condition of the connector of ECU during the check. INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS IN–31 HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE 1. For troubleshooting, diagnostic trouble code charts or problem symptom charts are provided for each circuit with detailed inspection procedures on the following page. 2. When all the component parts, wire harnesses and connectors of each circuit 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 performed without the problem symptoms occurring, the instruction will be to check and replace the ECU, even if the problem is not in the ECU. So, always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method. 3. 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. Check Wire Harness and Connector The problem in the wire harness or connector is an open circuit or a short circuit. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty contact in the connector, a connector terminal pulled out, etc. HINT: 1. It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In partic– ular, carefully check the connectors of sensors and actuators. 2. Faulty contact could be due to rusting of the connector terminals, to foreign materials entering termi– nals or a drop in the contact pressure between the male and female terminals of the connector. 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 abnormality 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 harness or con– nectors. SHORT CIRCUIT: This could be due to a short circuit between the wire harness and the body ground or to a short inside the switch, etc. HINT: • When there is a short between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly. IN–32 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS 1. CONTINUITY CHECK (OPEN CIRCUIT CHECK) (1) Disconnect the connectors at both ECU and sensor sides. (2) Measure the resistance between the applicable ter– minals of the connectors. Resistance: 1
or less HINT: • Measure the resistance while lightly shaking the wire harness vertically and horizontally. • When tester probes are inserted into a connector, insert the probes from the back. For waterproof connectors in which the probes cannot be inserted from the back, be careful not to bend the termianls when inserting the tester probes. 2. RESISTANCE CHECK (SHORT CIRCUIT CHECK) (1) Disconnect the connectors at both ends. (2) Measure the resistance between the applicable ter– minals 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. 3. VISUAL CHECK AND CONTACT PRESSURE CHECK (1) Disconnect the connectors at both ends. (2) Check for rust or foreign material, etc. on the termi– nals of the connectors. (3) Check crimped portions for looseness or damage and check if the terminals are secured in the lock position. HINT: The terminals should not come out when pulled lightly. (4) Prepare a test male terminal and insert it in the female terminal, then pull it out. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS IN–33 Actual examples of the inspection method for open circuit and short circuit are explained below. 1. OPEN CIRCUIT CHECK For the open circuit in the wire harness in Fig. 1, perform “(a) Continuity Check” or “(b) Voltage Check” to locate the section. (a) Continuity Check (1) Disconnect connectors (A) and (C) and measure the resistance betwen them. In the case of Fig. 2, Between terminal 1 of connector (A) and terminal 1 of connector (C)→ No continuity (open) Between terminal 2 of connector (A) and terminal 2 of connector (C)→ Continuity Therefore, it is found out that there is an open circuit between terminal 1 of connector (A) and terminal 1 of connector (C). (2) Disconnect connector (B) and measure the resistance between connectors (A) and (B), (B) and(C), In the case of Fig. 3, Between terminal 1 of connector (A) and terminal 1 of connector (B)→Continuity Between terminal 1 of connector (B) and terminal 1 of connector (C)→No Continuity (open) Therefore, it is found out that there is an open circuit between terminal 1 of connector (B) and termi nal 1 of connector (C). IN–34 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS (b) Voltage Check In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check. (1) As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector (A) at the ECU 5 V output terminal, terminal 1 of connector (B), and terminal 1 of connector (C), in that order. If the results are: 5 V: Between Terminal 1 of connector (A) and Body Ground 5 V: Between Terminal 1 of connector (B) and Body Ground 0 V: Between Terminal 1 of connector (C) and Body Ground then it is found out that there is an open circuit in the wire harness between terminal 1 of (B) and terminal 1 of (C). 2. SHORT CIRCUIT CHECK If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a “continuity check with ground”. INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED – SYSTEMS IN–35 (a) Continuity Check with Ground (1) Disconnect connectors (A) and (C) and measure the resistance between terminals 1 and 2 of connector (A) and body ground. In the case of Fig. 6, Between terminal 1 of connector (A) and body ground → Continuity Between terminal 2 of connector (A) and body ground → No continuity (open) Therefore, it is found out that there is a short circuit between terminal 1 of connector (A) and terminal 1 of connector (C). (2) Disconnect connector (B) and measure the resistance between terminal 1 of connector (A) and body ground, and terminal 1 of connector (B) and body ground. Between terminal 1 of connector (A) and body ground → No continuity (open) Between terminal 1 of connector (B) and body ground → Continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector (B) and terminal 1 of connector (C). IN–36 INTRODUCTION – HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Check and Replace ECU First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a known good one and check if the symptoms appear. (1) Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1
or less (2) Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure. IN–37 INTRODUCTION – VEHICLE LIFT AND SUPPORT LOCATIONS VEHICLE LIFT AND SUPPORT LOCATIONS IN–38 INTRODUCTION – ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL ABS Anti–Lock Brake System ALR Automatic Locking Retractor A/T Automatic Transaxle ATF Automatic Transmission Fluid BDC Bottom Dead Center BTDC Before Top Dead Center Calif. California Circuit Breaker CRS Child Restraint System Dash Pot ECU Electronic Control Unit ELR Emergency Locking Retractor ESA Electronic Spark Advance Exhaust (Manifold, Valve) Ex. Except FIPG Formed in Place Gasket Fusible Link Front Ignition Intake (Manifold, Valve) J/B Junction Block LED Light Emitting Diode Left – Hand LSPV Load Sensing Proportioning Valve Max. Maximum Min. Minimum Multipurpose M/T Menusl Trsnsaxls 0/D, OD Overdrive 0/S PCV Positive Crankcase Ventilation PKB Parking Brake Oversize Power Steering Right–Hand Rear SRS Supplemental Restraint System SSM Special Service Materials SST Special Service Tools STD Standard Switch IN–39 INTRODUCTION – ABBREVIATIONS USED IN THIS MANUAL TDC Top Dead Center TEMP. T/M Temperature Transmission TMC Toyota Motor Corporation TM M Toyota Motor Manufacturing U.S.A., Inc. u/s vcv Undersize Vacuum Control Valve VSV Vacuum Switching Valve VTV Vacuum Transmitting Valve With W/O Without IN–40 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS GLOSSARY OF SAE AND TOYOTA TERMS This glossary lists all SAE–J1930 terms and abbreviations used in this manual in compliance with SAE recommendations, as well as their Toyota equivalents. SAE ABBREVI– ATIONS TOYOTA TERMS ( )–ABBREVIATIONS SAE TERMS A/C Air Conditioning Air Conditioner ACL Air Cleaner Air Cleaner AIR Secondary Air Injection Air Injection (AI) Accelerator Pedal Battery Positive Voltage + B, Battery Voltage BARO Barometric Pressure CAC Charge Air Cooler Intercooler CARB Carburetor Carburetor CFI Continuous Fuel Injection CKP Crankshaft Position Crank Angle Closed Loop Closed Loop CM P CPP Camshaft Position Cam Angle CTOX Continuous Trap Oxidizer CTP Closed Throttle Position Idle ON (IDL ON) D FI Direct Fuel Injection (Diesel) Direct Injection (DI) DLC1 DLC2 DLC3 Data Link Connector 1 Data Link Connector 2 Data Link Connector 3 1: Check Connector 2: Toyota Diagnosis Comunication Link (TDCL) 3: OBDII Diagnostic Connector DTC Diagnostic Trouble Code Diagnostic Code DTM Diagnostic Test Mode EC L Engine Control Level ECM Engine Control Module ECT Engine Coolant Temperature Coolant Temperature, Water Temperature (THW) EEPROM Electrically Erasable Programmable Read Only Memory Electrically Erasable Programmable Read Only Memory (EEPROM). Erasable Programmable Read Only Memory (EPROM) EFE Early Fuel Evaporation Cold Mixture Heater (CMH), Heat Control Valve (HCV) EG R Exhaust Gas Recirculation Exhaust Gas Recirculation (EGR) Electronic Ignition Toyota Distributorless Ignition (TDI) Clutch Pedal Position Distributor Ignition EPROM EVAP Engine ECU (Electronic Control Unit) Engine Modification Engine Modification (EM) Erasable Programmable Read Only Memory Programmable Read Only Memory (PROM) Evaporative Emission Evaporative Emission Control (EVAP) Fan Control FEEPROM Flash Electrically Erasable Programmable Read Only Memory FEPROM Flash Erasable Programmable Read Only Memory Flexible Fuel Fuel Pump Fuel Pump Generator Alternator GND Ground Ground (GND) H02S Heated Oxygen Sensor Heated Oxygen Sensor (H02S) GEN IN–41 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS Idle Air Control Idle Speed Control (ISC) IAT Intake Air Temperature Intake or Inlet Air Temperature ICM Ignition Control Module IAC Indirect Fuel Injection Indirect Injection IFS Inertia Fuel–Shutoff ISC Idle Speed Control Knock Sensor Knock Sensor MAF Mass Air Flow Air Flow Meter MAP Manifold Absolute Pressure Manifold Pressure Intake Vacuum Mixture Control Electric Bleed Air Control Valve (EBCV) Mixture Control Valve (MCV) Electric Air Control Valve (EACV) MDP Manifold Differential Pressure MFI M ultiport Fuel Injection Electronic Fuel Injection (EFI) MIL Malfunction Indicator Lamp Check Engine Light MST Manifold Surface Temperature MVZ Manifold Vacuum Zone NVRAM Non–Volatile Random Access Memory O2S Oxygen Sensor Oxygen Sensor, Ot Sensor (OtS) On –Board Diagnostic On–Board Diagnostic (OBD) Oxidation Catalytic Converter Oxidation Catalyst Converter (OC), CCo Open Loop Open Loop PAIR Pulsed Secondary Air Injection Air Suction (AS) PCM Powertrain Control Module OBD PNP Park/Neutral Position PROM Programmable Read Only Memory PSP Power Steering Pressure PTOX Periodic Trap Oxidizer Diesel Particulate Filter (DPF) Diesel Particulate Trap (DPT) RAM Random Access Memory Random Access Memory (RAM) Relay Module ROM Read Only Memory Read Only Memory (ROM) RPM Engine Speed Engine Speed Supercharger SCB Supercharger Supercharger Bypass SFI Sequential Multiport Fuel Injection Electronic Fuel Injection (EFI), Sequential Injection SPL Smoke Puff Limiter SRI Service Reminder Indicator S RT System Readiness Test Scan Tool Throttle Body Throttle Body Throttle Body Fuel Injection Single Point Injection Central Fuel Injection (Ci) Turbocharger Turbocharger TCC Torque Converter Clutch TCM Transmission Control Module Torque Converter Transmission ECU (Electronic Control Unit) Throttle Position Throttle Position TBI Transmission Range IN–42 INTRODUCTION – GLOSSARY OF SAE AND TOYOTA TERMS TVV Thermal Vacuum Valve Bimetallic Vacuum Switching Valve (BVSV) Thermostatic Vacuum Switching Valve (TVSV) TWC Three–Way Catalytic Converter Three–Way Catalytic (TWC) CCRo TWC+OC Three–Way + Oxidation Catalytic Converter CCR+ CCo VAF Volume Air Flow Air Flow Meter Voltage Regulator Voltage Regulator VSS Vehicle Speed Sensor Vehicle Speed Sensor (Read Switch Type) WOT Wide Open Throttle Full Throttle WU–OC Warm Up Oxidation Catalytic Converter WU –TWC Warm Up Three–Way Catalytic Converter 3GR Third Gear 4G R Fourth Gear Manifold Converter IN–43 INTRODUCTION – STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS HOW TO DETERMINE BOLT STRENGTH Class Mark Hexagon head bolt 4– 5– 6– 7– 8– 9– 10– 11– 4T 5T 6T 7T 8T 9T 10T 11T Mark Stud bolt No mark Hexagon flange bolt w/ washer hexagon bolt Hexagon head bolt Hexagon flange bolt w/ washer hexagon bolt Hexagon head bolt Hexagon head bolt No mark 2 protruding lines 2 protruding lines 3 protruding lines 4 protruding lines Welded bolt Class IN–44 INTRODUCTION – STANDARD BOLT TORQUE SPECIFICATIONS SPECIFIED TORQUE FOR STANDARD BOLTS Class 1 OT 11T Diameter mm Pitch mm Specified torque Hexagon head bolt Hexagon flange bolt MA–1 MAINTENANCE – MAINTENANCE MA–2 MAINTENANCE – (5S–FE) (5S–FE) MAINTENANCE SCHEDULE SCHEDULE A CONDITIONS: Towing a trailer, using a camper or car top carrier. Repeated short trips of less than 8 km (5 miles) with outside temperature remaining below freezing. Extensive idling and/or low speed driving for long distances, such as police, taxi or door–to –door delivery use. Operating on dusty, rough, muddy or salt spread roads. Maintenance operation: A = Check and adjust if necessary. R = Replace, change or lubricate. I = Inspect and correct or replace if necessary. System Service interval (Use odometer reading or months, whichever comes first) Maintenance services beyond 96,000 km (60,000 miles) should continue to be performed at the same intervals shown for each maintenance schedule. 1,000 km Maintenance items ENGINE 1,000 miles 3.75 11.25 18.75 22.5 26.25 33.75 41.25 Drive belts Engine coolant EVA P BRAKES Months 56.25 MA–6 (item 1) MA–10 A: Every 72 months (item 12) MA–6 (item 2) I: First period 96,000 km (60,000 miles) or 72 months. I: After that every 12,000 km (7,500 miles) or 12 months. R: Every 6 months Engine oil and oil filter* IGNITION 52.5 Timing belt (1) Valve clearance FUEL 48.75 See page (item No.) MA–8 (item 6) MA–8 (item 7) R: First period 72,000 km (46,000 miles) or 36 months. R: After that every 48,000 km (30,000 miles) or 24 months. Exhaust pipes and mountings I: Every 24 months MA–10 (item 11) Air filter (2)* I: Every 6 months A: Every 36 months MA–7 (item 3, 4) Fuel lines end connections (3) I: Every 36 months MA–9 (item 10) Fuel tank cap gasket R; Every 72 months MA–9 (item 9) Spark plugs (Platinum tipped type) R; Every 72 months MA–7 (item 5) Charcoal canister (4) I; Every 72 months MA–9 (item 8) Brake linings and drums (6) I: Every 12 months MA–1 1 (item 15) Brake pads and discs (Front and rear) I; Every 12 months MA–10 (item 14) Brake line pipes and hoses I: Every 24 months MA–10 (item 13) MA–3 MAINTENANCE System Service interval (Use odometer reading or months, whichever comes first) Maintenance items CHASSIS – (5S–FE) Maintenance services beyond 96,000 km (60,000 miles) should continue to be performed at the same intervals shown for each maintenance schedule. , 1,000 km 1,000 miles Months 3.75 11.25 18.75 22.5 26.25 Drive shaft boots baIl joints and dust covers Manual t anaaxle, automatic tansaxie and differential (6) Steering gear housing oil (7) Bolts and nuts on chassis and body (8) 33.75 37.5 41.25 48.75 56.25 I: Every 12 months Steering linkage SRS airbag See page (item No.) MA–12 (item 16) MA–12 (item 17) I; First period 10 years. I: After that every 2 years. I; Every 12 months MA–13 (item 19) I: Everv 12 month: MA–1 3 (item 20) MA–14 R; Every 24 months (item 21, 22) I: Every 24 months MA–1 3 (item 18) f: Every 12 months MA–1 5 (item 23) * marks indicates maintenance which is part of the warranty conditions for the Emission Control Systems. The warranty period is in accordance with the owner’s guide or the warranty booklet. *: California and New York specification vehicles (1) Applicable to vehicles operated under conditions of extensive idling and/or low speed driving for long distances such as police, taxi or door–to–door delivery use. (2) Applicable when operating mainly on dusty roads. (3) Includes inspection of fuel tank band and vapor vent system. (4) Non –maintenance item except for California and New York. (5) Also applicable to drum lining for parking brake. For other usage conditions, refer to SCHEDULE B. (6) Check for leakage. (7) Check for oil leaks from steering gear housing. (8) Applicable only when operating mainly on rough, muddy roads. The applicable parts are listed below. For other usage conditions, refer to SCHEDULE B. Front and rear suspension member to cross body. Strut bar bracket to body bolts. Bolts for seat installation. MA–4 MAINTENANCE – (5S–FE) SCHEDULE B CONDITIONS: Conditions others than those listed for SCHEDULE A. Maintenance operation: A = Check and adjust if necessary. R = Replace, change or lubricate. I = Inspect and correct or replace if necessary. system Service interval (Use odometer reading or months, whichever comes first) Maintenance services beyond 96,000 km (60,000 miles) should continue to be performed at the same Intervals shown for each maintenance schedule. Maintenance items ENGINE 1,000 km 1,000 miles Months 7.6 22.5 37.5 A: Every 72 months Volvo clearance Drive belt I: First period 96,000 km (60,000 miles) or 72 months. I: After that every 12,000 km (7,500 miles) or 12 months. R: Every 12 months Engine oil and oil filter* Engine coolant FUEL IGNITION EVAP BRAKES CHASSIS See page (item No.) R: First period 72,000 km (45,000 miles) or 36 months. R: After that every 48,000 km (30,000 miles) or 24 months. Exhaust pipes and mountings I: Every 36 months Air filter* R: Every 36 months MA–10 (item 12) MA–6 (item 2) MA– 8 (item 6) MA–8 (item 7) MA–1 0 (item 11) MA–7 (item 3, 4) Fuel line’ and connections (1) I: Every 36 month: MA– 9 (item 10) Fuel tank cap gasket R: Every 72 months MA–9 (item 9) Spark pluq:(Platinum tipped type) R: Every 72 months MA–7 (item 5) Charcoal canister (2) I; Every 72 months MA– 9 (item 8) Brake linings end drums (3) I: Even 24 months MA–1 1 (item 15) Brake pads and discs I: Every 24 months MA– 10 (item 14) Brake line pipes and hoses (Front and rear) I: Every 24 months MA–10 (item 13) Steering linkage !: Every 24 months MA–12 (item 16) SRS airbag MA–12 (item 17) I: First period 10 years. I: After that every 2 years. I: Every 24 months MA–1 3 (item 19) i: Every 24 months MA– 13 (item 20) Man^aI transaxle, automatic transaxle and differential (4) I: Every 24 months MA– 14 (item 21, 22) Steering goof housing oil (5) I: Every 24 months MA–13 (item 18) Bolts and nuts on chassis and body (6y I: Every 24 months MA–1 5 (item 23) Drive shaft boots ^aII joints and dust covers * marks indicates maintenance which is part of the warranty conditions for the Emission Control Systems. The warranty period is in accordance with the owner’s guide or the warranty booklet, *; California and New York specification vehicles (1) Includes inspection of fuel tank band and vapor vent system. (2) Non–maintenance item except for California and New York. (3) Also applicable to drum lining for parking brake. (4) Check for leakage. (5) Check for oil leaks from steering gear housing. (6) The applicable parts are listed below. • Front and rear suspension member to cross body. • Strut bar bracket to body bolt. Bolts for seat installation. MA–5 MAINTENANCE – (5S–FE) PREPARATION EQUIPMENT Belt tension gauge Dial indicator or dial indicator with magnetic base Micrometer Brake hose Mirror Steel square Tachometer Torque wrench Vernier calipers COOLANT Item Engine coolant (w/ Heater) Capacity 6.3 liters (6.7 US qts, 5.5 Imp. qts) Classification Ethylene–glycol base LUBRICANT Item Engine oil (M/T) Dry fill Drain and refill w/ Oil filter change w/o Oil filter change Engine oil (A/T) Dry fill Drain and refill w/ Oil filter change w/o Oil filter change Capacity 4.2 liters (4.4 US qts, 3.7 Imp. qts) Classification API grade SG or SH, Energy –Conserving ΙΙ mutigrade engine oil or ILSAC multigrade engine oil and recommended viscosity oil 3.6 liters (3.8 US qts, 3.2 Imp. qts) 3.4 liters (3.6 US qts, 3.0 Imp. qts) 4.3 liters (4.5 US qts, 3.8 Imp. qts) 3.18 liters (3.8 US qts, 3.2 Imp. qts) 3.4 liters (3.6 US qts, 3.0 Imp. qts) Manual transaxle oil (w/ Differential oil) 2.6 liters (2.7 US qts, 2.3 Imp. qts) AN GL–3 SAE 75W–90 In case the above is unvailable API GL–4 or GL–5 SAE 75w–90 Automatic transaxle fluid Dry fill Drain and refill Differential oil 5.18 liters (5.9 US qts, 4.9 Imp. qts) 2.5 liters (2.6 US qts, 2.2 Imp. qts) 1.6 liters (1.7 US qts, 1.4 Imp. qts) ATF DEXRON ΙΙ ATF DEXRON ΙΙ MA–6 MAINTENANCE – (5S–FE) MAINTENANCE OPERATIONS Cold Engine Operations 1. REPLACE TIMING BELT (a) Remove the timing belt. (See page EG–26) (b) Install the timing belt. (See page EG–33) 2. INSPECT DRIVE BELTS (a) Visually check the belt for excessive wear, frayed cords etc. If necessary, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced. (b) Using a belt tension gauge, measure the drive belt tension. Belt tension gauge: Nippondenso BTG–20 (95506–00020) Borroughs No.BT – 33 – 73F Drive belt tension: Generator (w/ A/C) New belt 175 ± 5 lbf Used belt 130 ± 10 lbf Generator (w/o A/C) New belt 125 ± 25 lbf Used belt 95 ± 20 Ibf PS pump New belt 125 ± 25 lbf Used belt 80 ± 20 lbf If necessary, adjust the drive belt tension. HINT: • ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. • Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. • After installing the belt, check that it fits properly in the ribbed grooves. MA–7 MAINTENANCE – (5S–FE) • Check by hand to confirm that .the belt has not slipped out of the groove on the bottom of the pulley. • After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. 3. INSPECT AIR FILTER (a) Visually check that the air filter is not damaged or excessively oily. If necessary, replace the air filter element. (b) Clean the air filter with compressed air. First blow from the inside thoroughly, then blow off the outside of the air filter. 4. REPLACE AIR FILTER Replace the air filter with a new one. 5. REPLACE SPARK PLUGS (a) Disconnect the spark plug cords at the rubber boot. DO NOT pull on the cords. (b) Using a 16 mm plug wrench, remove the spark plugs. (c) Check the electrode gap of new spark plugs. Correct electrode gap: 1.1 mm (0.043 In.) Recommended spark plugs: PK20R11 for ND BKR6EP11 for NGK NOTICE: If adjusting the gap of a now plug, bend only the base of the ground electrode. Do NOT touch the tip. Never attempt to adjust the gap on a used plug. MA–8 MAINTENANCE – (5S–FE) (d) Using a 16 mm plug wrench, reinstall the spark plugs. Torque: 18 N–m (180 kgf–cm, 13 ft–lbf) (e) Reconnect the spark plug cords. 6. REPLACE ENGINE OIL AND OIL FILTER (See page EG–274) Oil grade: API grade SG or SH, Energy–Conserving II multi– grade engine oil or ILSAC multigrade engine oil. Recommended viscosity Is as shown in the illustra– tion. Drain and refill capacity: M/T w/ Oil filter change 3.6 liters (3.8 US qts, 3.2 Imp. qts) w/o Oil filter change 3.4 liters (3.6 US qts, 3.0 Imp. qts) A/T w/ Oil filter change 3.6 liters (3.8 US qts, 3.2 Imp. qts) w/o Oil filter change 3.4 liters (3.6 US qts, 3.0 Imp. qts) 7. REPLACE ENGINE COOLANT (See page EG–241) HINT: • Use a good brand of ethylene–glycol base engine coolant and mix it according to the manufacturer ’s instructions. • Using engine coolant which includes more than 5096 ethylene–glycol (but not more than 70%) is recommended. NOTICE: • Do not use alcohol type coolant. • The engine coolant should be mixed with demineral– ized water or distilled water. Capacity (w/ Heater): 6.3 liters (6.7 US qts, 5.5 Imp. qts) MA–9 MAINTENANCE – (5S–FE) 8. INSPECT CHACOAL CANISTER (a) Visually inspect the canister case. (b) Check for clogged filter and stuck check valve. • Using low pressure compressed air (4.71 kPa, 48 gf/cmT, 0.68 psi), blow into port A and check that air flows without resistance from the other ports. • Blow low pressure compressed air (4.71 kPa, 48 gf/cm2, 0.68 psi) into port B and check that air does not flow from the other ports. If a problem is found, replace the charcoal canister. (c) Clean filter in canister. • Clean the filter by blowing 294 kPa (3 kgf/cm’, 43 psi) of compressed air into port A while hold– ing port B closed. NOTICE: • Do not attempt to wash the canister. • No activated carbon should come out. 9. REPLACE GASKET IN FUEL TANK CAP (a) Remove the old gasket from the tank cap. NOTICE: Do not damage the tank cap. (b) Install a new gasket by hand. (c) Check the cap for damage or cracks. (d) Reinstall the cap and check the torque limiter. 10. INSPECT FUEL LINES AND CONNECTIONS Visually check the fuel lines for cracks, leakage, loose connections, deformation or tank band looseness. MA–10 MAINTENANCE – (5S–FE) 11. INSPECT EXHAUST PIPES AND MOUNTINGS Visually check the pipes, hangers and connections for severe corrosion, leaks or damage. 12. ADJUST VALVE CLEARANCE (See page EG –12) Valve clearance (Cold): Intake 0.19 – 0.29 mm (0.007 – 0.011 In.) Exhaust 0.28 – 0.38 mm (0.011 – 0.015 In.) BRAKES 13. 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 left before checking the front brake. (a) Check all brake lines and hoses for: • Damage • Wear • Deformation • Cracks • Corrosion • Leaks • Bends • Twists (b) Check all clamps for tightness and connections for leakage. (c) Check that the hoses and lines are clear of sharp edges, moving parts and the exhaust system. (d) Check that the lines installed in grommets pass thr– ough the center of the grommets. 14. INSPECT FRONT AND REAR BRAKE PADS AND DISCS (a) Check the thickness of the disc brake pads and check for irregular wear. Minimum pad thickness: 1.0 mm (0.039 in.) MA–11 MAINTENANCE – (5S–FE) HINT: If a squealing or scraping noise comes from the brake during driving, check the pad wear indicator to see if it is contacting the disc rotor. If so, the disc pad should be replaced. (b) Check the disc for wear or runout. Minimum disc thickness: Front 26.0 mm (1.024 in.) Rear 9.0 mm (0.354 In.) Maximum disc runout: Front 0.05 mm (0.0020 in.) Rear 0.15 mm (0.0059 in.) 15. INSPECT BRAKE LININGS AND DRUMS (a) Check the lining – to – drum contact condition and lining wear. Minimum lining thickness: 1.0 mm (0.0039 in.) (b) Check the brake drums for scoring or wear. Maximum drum inside diameter: Drum brake 230.6 mm (9.079 in.) Disc brake 171.0 mm (6.732 in.) (c) Clean the brake parts with a damp cloth. NOTICE: Do not use compressed air to clean the brake parts. (d) Disc brake: Settle the parking brake shoes and drum. When per– forming the road test in item 25, do the following: • Drive the vehicle at approx. 50 km/h (30 mph) on a safe, level and dry road. • With the parking brake release knob pushed in, pull on the lever with 88 N (9 kgf, 20 lbf) of force. • Drive the vehicle for approx. 400 m (1 /4 mile) in this condition. • Repeat this procedure 2 or 3 times. Check parking lever travel. If necessary, adjust the parking brake. MA–12 MAINTENANCE – (5S–FE) CHASSIS I6. INSPECT STEERING LINKAGE (a) Check the steering wheel freeplay. Maximum steering wheel freeplay: 30 mm (1.18 In.) With the vehicle stopped and the front wheels point– ing straight ahead, rock the steering wheel gently back and forth with light finger pressure. (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. 17. INSPECT SRS AIRBAG Driver Airbag: Visually inspect the steering wheel pad (airbag and inflater). • Use the diagnosis check to check if there are abnormalities. • Check that there are no cuts, cracks or noticeable color changes on the surface of the steering wheel pad or in the center groove of the pad. • Remove the steering wheel pad from the vehicle and check the wiring and steering wheel for damage and corrosion due to rusting, etc. If necessary, replace the steering wheel pad. Front Passenger Airbag: Visually inspect the front passenger airbag assembly (airbag and inflater). • Use the diagnosis check to check if there are abnormalities. • Check that there are no cuts, cracks or noticeable color changes in the front passenger airbag door. MA–13 MAINTENANCE – (5S–FE) • Remove the front passenger airbag assembly from the vehicle and check the wiring and front passenger airbag door for damage and corrosion due to rusting, etc. If necessary, replace the front passenger airbag as– sembly. CAUTION: • For removal and replacement of the steering wheel pad or front passenger airbag assembly, see page RS–19 or 31 and be sure to perform the operation in the correct order. • Before disposing of the steering wheel pad or front passenger airbag assembly, it must first be deployed by using SST (See page RS–22 or 35). 18. INSPECT STEERING GEAR HOUSING OIL Check the steering gear housing for oil leakage. 19. INSPECT DRIVE SHAFT BOOTS Check the drive shaft boots for clamp looseness, leak– age or damage. 20. INSPECT BALL JOINTS 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 tires. • Lower the jack until there is about half a load on the front coil spring. Place stands under the vehi– cle for safety. • Check that the front wheels are in a straight forward position, and block them with chocks. Using a lever, pry up the end of the lower arm, and check the amount of play. Maximum ball joint vertical play: 0 mm (0 in.) If there is play, replace the ball joint. (b) Check the dust cover for damage. MA–14 MAINTENANCE – (5S–FE) 21. CHECK TRANSAXLE OIL (FLUID) (a) Visually check the transaxle for oil (fluid) leakage. If leakage is found, check for the cause and repair. 22. REPLACE TRANSAXLE OIL (FLUID) A. M/T: Replace transaxle oil (a) Remove the filler and drain plugs, and drain the oil. (b) Reinstall the drain plug securely. (c) Add new oil until it begins to run out of the filler hole. Recommended transaxle oil: Oil grade API GL–3 Viscosity SAE 75W–90 Capacity: 2.6 liters (2.7 US qts, 2.3 Imp. qts) In case the above oil grade is unavailable, use type A or B. Type A: Oil grade API GL–4 Viscosity SAE 75W–90 Type B: Oil grade API GL–5 Viscosity SAE 75W–90 (d) Reinstall the filler plug securely. B. A/T: Replace transaxle fluid Transmission: (a) Using a 10 mm hexagon wrench, remove the drain plug and drain the fluid. (b) Reinstall the drain plug securely. (c) With the engine OFF, add new fluid through the dip– stick tube. Transmission fluid: ATF DEXRON II Drain and refill capacity: 2.5 liters (2.6 US qts, 2.2 Imp. qts) (d) Start the engine and shift the selector into all posi– tions from “P” through “L”, and then shift into “P”. MA–15 MAINTENANCE – (5S–FE) (e) With the engine idling, check the fluid level. Add fluid up to the “COOL” level on the dipstick. NOTICE: Do not overfill. The transmission and differen– tial are separate units. (f) Recheck the fluid level at the normal operating tem– perature (70 – 80
C (158 –176
F)) and add as neces– sary. Differential: (a) Remove the filler plug. (b) Using a 10 mm hexagon wrench, remove the drain plug and drain the fluid. (c) Reinstall the drain plug securely. (d) Add new fluid until it begins to run out of the filler hole. Differential fluid: ATF DEXRON II Capacity: 1.6 liters (1.7 US qts, 1.4 Imp. qts) (e) Reinstall the filler plug securely. 23. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY Tighten the following parts: • Front seat mount bolts Torque: 37 N–m (375 kgf–cm, 27 ft–lbf) • Front suspension member–to–body mounting bolts Torque: 181 N–m (1,850 kgf–cm, 134 ft–lbf) MA–16 MAINTENANCE – (5S–FE) • Rear suspension member – to – body mounting nuts Torque: 51 N–m (520 kgf–cm, 38 ft–lbf) 24. BODY INSPECTION (a) Check the body exterior for dents, scratches and rust. (b) Check the underbody for rust and damage. If necessary, replace or repair. 25. ROAD TEST (a) Check the engine and chassis for abnormal noises. (b) Check that the vehicle does not wander or pull to one side. (c) Check that the brakes work properly and do not drag. 26. FINAL INSPECTION (a) Check the operation of the body parts: Hood: Auxiliary catch operates properly Hood locks securely when closed • Front and rear doors: Door lock operates properly Doors close properly • Luggage compartment door and back door: Door lock operates properly Seats: Seat adjusts easily and locks securely in any position Front seat back locks securely in any position Folding–down rear seat backs lock securely (b) Be sure to deliver a clean car. Especially check: • Steering wheel • Shift lever knob • All switch knobs • Door handles • Seats MA–17 MAINTENANCE GENERAL MAINTENANCE These are some maintenance and inspec– tion items which are considered to be the owner’s responsibility. They can be perfo– rmed by the owner or he can have them done at a service shop. These items in– clude 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 perform. Items and procedures for general maintenance are as follows: OUTSIDE VEHICLE 1. TIRES (a) Check the pressure with a gauge. Adjust if necessary. (b) Check for cuts, damage or excessive wear. 2. WHEEL NUTS When checking the tires, check the nuts for looseness or for missing nuts. If neces– sary, tighten them. 3. TIRE ROTATION It is recommended that tires be rotated every 12,000 km (7,500 miles). 4. WINDSHIELD WIPER BLADES Check for wear or cracks whenever they do not wipe clean. Replace if necessary. 6. FLUID LEAKS (a) Check underneath for leaking fuel, oil, water or other fluid. (b) If you smell gasoline fumes or notice any leak, have the cause found and corrected. 6. DOORS AND ENGINE HOOD (a) Check that all doors including the trunk lid and back door 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. INSIDE VEHICLE 7. LIGHTS (a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working. (b) Check the headlight aim. 6. WARNING LIGHTS AND BUZZERS – (5S–FE) Check that all warning lights and buzzers function properly. 9. HORN Check that it is working. 10. WINDSHIELD GLASS Check for scratches, pits or abrasions. 11. WINDSHIELD WIPER AND WASHER (a) Check operation of the wipers and washer. (b) Check that the wipers do not streak. 12. WINDSHIELD DEFROSTER Check that the air comes out from the defroster outlet when operating the heater or air conditioner at defroster mode. 13. REAR VIEW MIRROR Check that it is mounted securely. 14. SUN VISORS Check that they more freely and mounted securely. 15. STEERING WHEEL Check that it has the specified freeplay. Be alert for changes in steering condition, such as hard steering, excessive freeplay or strange noise. 16. SEATS (a) Check that all front seat controls such as seat adjusters, seatback recliner, etc. op– erate smoothly. (b) Check that all latches lock securely in any position. (c) Check that the locks hold securely in any latches position. (d) Check that the head restraints move up and down smoothly and that the locks hold securely in any latched position. (e) For folding–down rear seat backs, check that the latches look securely. 17. SEAT BELTS (a) Check that the seat belt system such as buckles, retractors and anchors operate properly and smoothly. (b) Check that the belt webbing is not cut, frayed, worn or damaged. 18. ACCELERATOR PEDAL Check the pedal for smooth operation and uneven pedal effort or catching. 19. CLUTCH PEDAL (See page CL–6) Check the pedal for smooth operation. Check that the pedal has the proper freeplay. MA–18 MAINTENANCE 20. BRAKE PEDAL (See page BR–8) (a) Check the pedal for smooth operation. (b) Check that the pedal has the proper re– serve distance and freeplay. (c) Check the brake booster function. 21. BRAKES At a safe place, check that the brakes do not pull to one side when applied. 22. PARKING BRAKE (See page BR–10) (a) Check that the lever has the proper travel. (b) On a safe incline, check that the vehicle is help securely with only the parking brake applied. 23. AUTOMATIC TRANSMISSION PARK MECHANISM (a) Check that lock release button of the se– lector lever for proper and smooth opera– tion. (b) On a safe incline, check that the vehicle is held securely with the selector lever in the ”P” position and all brakes released. UNDER HOOD 24. WINDSHIELD WASHER FLUID Check that there is sufficient fluid in the tank. 25. ENGINE COOLANT LEVEL Check that the coolant level is between the ”FULL” and ”LOW” lines on the see– through reservoir. 28. 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. 27. BATTERY ELECTROLYTE LEVEL Check that the electrolyte level of all bat– tery cells is between the upper and lower level lines on the case. If level low, add distilled water only. 28. BRAKE AND CLUTCH FLUID LEVELS (a) Check that the brake fluid level is near the upper level line on the see –through reser– voir. (b) Check that the clutch fluid level is within ±5 mm (0.20 in.) of the reservoir filling line. – (5S–FE) 29. ENGINE DRIVE BELTS Check all drive belts for fraying, cracks, wear or oiliness. 30. ENGINE OIL LEVEL Check the level on the dipstick with the engine turned off. 31. POWER STEERING FLUID LEVEL Check the level. The level should be in the “HOT” or “COLD” range depending on the fluid temperature. 32. AUTOMATIC TRANSMISSION FLUID LEVEL (a) Park the vehicle on a level surface. (b) With the engine idling and the’ parking brake applied, shift the selector into all positions from ”P” to ”L” and then shift into ”P”. (c) Pull out the dipstick and wipe off the fluid with a clean rag. Re–insert the dipstick and check that the fluid– level is in the HOT ran nge. (d) Perform this check with the fluid at normal driving temperature (70 – 80
C or 158– 176’ F). NOTE: Wait about 30 minutes before che– cking the fluid level after extended driving at high speeds in hot weather, driving in heavy traffic or with a trailer. 33. EXHAUST SYSTEM Visually inspect for cracks, holes or loose supports. If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located and corrected. MA–19 MAINTENANCE SERVICE SPECIFICATIONS SERVICE DATA Drive belt tension Generator (w/ A/C) New belt Generator (w/ A/C) Used belt Generator (w/o A/C) New belt Generator (w/o A/C) Use belt PS pump New belt PS pump Spark plug Spark plug Spark plug Recommended spark plug Used belt Recommended spark plug ND Correct electrode gap NGK Firing order Valve clearance Intake Valve clearance Exhaust Front and rear brake Pad thickness Minimum Disc thickness Front Disc thickness Rear Minimum Disc runout Front Maximum Disc runout Rear Maximum Minimum Parking brake Lining thickness Minimum Drum inside diameter Drum brake Maximum Drum inside diameter Disc brake Maximum Front axle and suspension Ball joint vertical play Maximum Steering wheel freeplay Maximum TORQUE SPECIFICATIONS Part tightended Front seat mounting bolts Front suspension member x Body Rear suspension member x Body – (5S–FE) MA–20 MAINTENANCE – (5S–FE) (1MZ–FE) MAINTENANCE SCHEDULE SCHEDULE A CONDITIONS: • Towing a trailer, using a camper or car top carrier. • Repeated short trips of less than 8 km (5 miles) with outside temperature remaining below freezing. • Extensive idling and/or low speed driving for long distances, such as police, taxi or door–to –door delivery use. • Operating on dusty, rough, muddy or salt spread roads. Maintenance operation: A = Check and adjust if necessary. R = Replace, change or lubricate. I = Inspect and correct or replace if necessary. System Service interval (Use odometer reading or months, whichever comes first.) Maintenance services beyond 98,000 km (60.000 miles) should continue to be poformed at the same intervals shown for each maintenance schedule. Maintenance items ENGINE x 1,000 km X 1,000 miles 3.75 11.25 18.75 22.5 I6.t6 33.76 37.6 Drive belt Engine coolant A: Evan 72 month: R: Every 6 months CHASSIS MA–27 (item 6) MA–27 (item 7) R: first period 72,040 km (46,000 mile:) or 36 months. R: After that every 48,000 km (30,000 miles) or 24 months. 1: Every 24 months MA–29 (item 11) Fuel tank cap gasket 1: Every 6 months MA–25 R: Every 36 month: (item 3, 4) M^–29 i: Every 36 months (item 10) MA–28 R: Even 72 months (item 9) Spark plugs (Platinum tipped type) R: Every 72 month: MA–25 (item 5) Charcoal canister (4) I: Every 72 month: MA–28 (item 8) Broke linings and drums (6) I: Every 12 months MA–30 (item 15) Air filter ^ty* Fuel lines and connections (3) BRAKES MA–29 (item 12) MA–24 (item 2) i: First period 96.000 km (80,000 miles) or 72 months. I: After that every 12,000 km (7,500 miles) or 12 month:. Exhavst pipe* and mountings EVAP See page (item No.) MA–24 (item 1) Engine oil and oil filter* IGNITION Month= Timing belt (1) valve clearance FUEL 48,7a 58.Z5 Broke pads and discs (Front and rev) I: Even 12 months MA–30 (item 14) Broke line pipes and hoses I: Every 24 month: MA–29 (item 13) I: Every 12 months MA–31 (item 16) Steering linkage SRS ahbap MA–¿¿ 1 (item 17) l: First period 10 years. I: After that every 2 years. Ba1I joints and dust covtr: I: Every 12 months Drive shaft boots I: Ev..y 12 months Automatic transmission and differential oil Steering gear housing oil (6) Bob and nuts on chassis and body (7) MA–33 (item 20) MA–32 (item 19) MA–33 R: Every 24 months (item 22) MA–32 I: Even 24 month: (item 18) I: Every 12 months MA–34 (item 23) MA–21 MAINTENANCE – (1MZ–FE)
.mark indicates maintenance which is part of the warranty conditions for the Emission Control Systems. The warranty period is in accordance with the owner’s guide or the warranty booklet. (
: California and New York specification vehicles) (1) Applicable to vehicles operated under conditions of extensive idling and/or low speed driving for long distances such as police, taxi or door–to–door delivery use. (2) Applicable when operating mainly on dusty roads. If not, apply SCHEDULE B. (3) Includes inspection of fuel tank band and vapor vent system. (4) Non –maintenance item except for California and New York. (5) Also applicable to drum lining for parking brake. For other usage conditions, refer to SCHEDULE B. (6) Check for oil leaks from steering gear housing. (7) Applicable only when operating mainly on rough, muddy roads. The applicable parts are listed below. For other usage conditions, refer to SCHEDULE B. • Front and rear suspension member to cross body. • Strut bar bracket to body. • Bolts for seat installation. MA–22 MAINTENANCE – (1MZ–FE) SCHEDULE B CONDITIONS: Conditions others than those listed for SCHEDULE A. Maintenance operation: A = Check and adjust if necessary. R = Replace, change or lubricate. I = Inspect and correct or replace if necessary. system Service interval (Use odometer reading or months, whichever comes first) Maintenance Items ENGINE Maintenance services beyond 98,000 km (84,000 mile:) should continue to be performed at the same Intervals shown for each maintenance schedule, 1,000 km 1,000 miles 7.5 22.6 37.5 52.5 A; Every 72 months Valve clearance Drive belt I: First period 98,000 km (60,000 miles) or 72 months. I: After that every 12,000 km (7,600 miles) or 12 months. Engine oil and oil filter* Engine coolant R; Every 12 months R: First period 72,000 km (46,000 miles) or 36 months. R: After that every 48,000 km (30,000 miles) or 24 months. I; Every 36 month: Exhaust pipes and mountings FUEL IGNITION EVAP BRAKES See page (item No.) MA–29 (item 12) MA–24 (item 2) MA–27 (item6) MA–27 (item 7) MA–24 (item 11) R: Every 36 months MA–25 (item 4) Fuel lines and connections (1) I: Every 36 months MA–29 (item 10) Fuel tank cap gasket R: Every 72 months MA–28 (item 9) R; Every 72 months MA–25 (item 5) nk filter* spark plugs (Platinum tipped type) Charcoal canister (2) Broke linings and drums (3) Brake pads and disc (Front and rear) CHASSIS Months I; Every 72 months MA–28 (item 8) I: Every 24 months MA–30 (item 15) I: Every 24 months MA–30 (item 14) Stake line pipes and hoses I: Every 24 months MA–29 (item 13) Steering linkage I; Every 24 months MA–31 (item 16) MA–31 (item 17) I; First period 10 years. I: After that every 2 years. I; Every 24 month: MA–33 (item 20) Drive shaft boots I: Every 24 months MA–32 (item 19) Automatic transmission and differential oil (4) I: Every 24 months MA–33 (item 22) i: Every 24 months MA–32 (item 18) Ball Jolnta and dust covers Steering gear housing oil (6) Bolts end nuts on chassis end body (6) I; Every 24 months MA–34 (item 23) * mark indicates maintenance which is part of the warranty conditions for the Emission Control Systems. The warranty period is in accordance with the owner’s guide or the warranty booklet. (*: California and New York specification vehicles) (1) Includes inspection of fuel tank band and vapor vent system. (2) Non–maintenance item except for California and New York. (3) Also applicable to drum lining for parking brake. (4) Check for leakage. (5) Check for oil leaks from steering gear housing. (6) The applicable parts are listed below. Front and rear suspension member to cross body. Strut bar bracket to body. Bolts for seat installation. MA–23 MAINTENANCE – (1MZ–FE) PREPARATION EQUIPMENT Belt tension gauge Dial indicator with magnetic base Micrometer Brake hose Mirror Steel square Thermometer Torque wrench Vernier calipers COOLANT Item Capacity 8.7 liters (9.2 US qts. 7.7 Imp. qts) Engine coolant Classification Ethylene–glycol base LUBRICANT Capacity Claasifioation Engine oil Drain and refill w/ Oil filter change w/o Oil filter change 4.7 liters (5.0 US qts, 4.1 Imp. qts) 4.5 liters (4.8 US qts, 4.0 Imp. qts) Automatic transaxle fluid Drain end refill API grade SG or SH, Energy –Conserving ΙΙ or ILSAC multigrede and recommended viscosity oil with SAE bW–30 being the preferred engine oil ATF DEXRON ΙΙ 3.5 liters (3.7 US qts, 3.1 Imp. qts) Differential fluid 0.95 liters (1.0 US qts, 0.8 Imp. qts) Item ATF DEXRON ΙΙ MA–24 MAINTENANCE – (1MZ–FE) MAINTENANCE OPERATIONS Cold Engine Operations 1. REPLACE TIMING BELT (a) Remove the timing belt. (See page EG–41) (b) Install the timing belt. (See page EG–49) 2. INSPECT DRIVE BELT (a) Visually check the belt for excessive wear, frayed cords etc. If necessary, replace the drive belt. HINT: Cracks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced. (b) Using a belt tension gauge, measure the drive belt tension. Belt tension gauge: Nippondenso BTG–20 (95508–00020) Borroug hs No. BT–33–73F Drive belt tension: Generator New belt 175 ± 5 lbf Used belt 115 + 20 lbf PS pump New belt 150 – 185 lbf Used belt 115± 20 lbf If nesessary, adjust the drive belt tension. HINT: “New belt” refers to a belt which has been used 5 miniutes or less on a running engine. “Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. After installing the belt, check that it fits properly in the ribbed grooves. Check by hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley. After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. MA–25 MAINTENANCE – (1MZ – FE) 3. INSPECT AIR FILTER (a) Visually check that the air filter is not excessively damaged or oily. (b) Clean the element with compressed air. First blow from the inside thoroughly, then blow off the outside of the air filter. 4. REPLACE AIR FILTER Replace the air filter with a new one. 5. REPLACE SPARK PLUGS (a) Using a 5 mm hexagon wrench, remove the 2 nuts and V–bank cover. (b) Disconnect the 6 ignition coil connectors from the RH and LH cylinder heads. (c) Remove the6 bolts and6 ignition coils from the RH and LH cylinder heads. HINT: Arrange the ignition coils in the correct order. MA–26 MAINTENANCE – (1MZ–FE) (e) Using a 16 mm plug wrench, remove the 6 spark plugs from the RH and LH cylinder heads. (f) Check the electrode gap of new spark plugs. Correct electrode gap: 1.1 mm (0.043 In.) Recommended spark plugs: PKZOR11 for ND BKR6EP–11 for NGK NOTICE: If adjusting the gap of a new plug, bend only the base of the ground electrode. DO NOT touch the tip. Never attempt to adjust the gap on a used plug. (g) Using a 16 mm plug wrench, reinstall the 6 spark plugs. Torque: 18 N–m (180 kgf.cm, 13 ft–lbf) (h) Reinstall the6 ignition coil with the6 bolts. Torque: 8 N–m (80 kgf–cm, 89 in.–lbf) (i) Reconnect the 6 ignition coil connectors. MA–27 MAINTENANCE – (1MZ–FE) (j) Using a 5 mm hexagon wrench, reinstall the V– bank cover with the 2 nuts. 6. REPLACE ENGINE OIL AND OIL FILTER (See page EG–372) Oil grade: API grade SG or SH, Energy–Conserving ΙΙ or ILSAC multigrade engine oil. Recommended visco sity is as shown in the Illustration with SAE 5W–30 being the preferred engine oil. Capacity: Drain and refill w/ 0il filter change 4.7 liters (5.0 US qts, 4.1 Imp. qts) w/o Oil filter change 4.5 liters (4.8 US qts, 4.0 Imp. qts) 7. REPLACE ENGINE COOLANT (See page EG–319) HINT: • Use a good brand of ethylene–glycol base engine coolant and mix it according to the manufacturer ’s instructions. • Using engine coolant which includes more than 5096 ethylene–glycol (but not more than 7096) is recommended. NOTICE: Do not use alcohol type coolant. The engine coolant should be mixed with demineral– ized water or distilled water. Capacity: 8.7 liters (9.2 US qts, 7.7 Imp. qts) MA–28 MAINTENANCE – (1MZ–FE) 8. INSPECT CHARCOAL CANISTER (a) Visually inspect the canister case. (b) Check for clogged filter and stuck check valve. Blow low pressure compressed air (4.71 kPa, 48 gf/cm
, 0.68 psi) into port A and check that air flows without resistance from the other ports. • Blow low pressure compressed air (4.71 kPa, 48 gf/cm
, 0.68 psi) into port B and check that air does not flow from the other ports. If a problem is found, replace the charcoal canister. (c) Clean filter in canister. Clean the filter by blowing 294 kPa (3 kgf/cm
, 43 psi) of compressed air into port A while hold– ing port B closed. NOTICE: • • Do not attempt to wash the canister. No activated carbon should come out. 9. REPLACE GASKET IN FUEL TANK CAP (a) Remove the old gasket from the tank cap. Do not damage the cap. (b) Install a new gasket by hand. (c) Check the cap for damage or cracks. (d) Install the cap and check the torque limiter. MA–29 MAINTENANCE – (1MZ–FE) 10. INSPECT FUEL LINES AND CONNECTIONS Visually check the fuel lines for cracks, leakage, loose connections, deformation or tank band looseness. 11. INSPECT EXHAUST PIPES AND MOUNTINGS Visually check the pipes, hangers and connections for severe corrosion, leaks or damage. 12. ADJUST VALVE CLEARANCE (See page EG –13) Valve clearance (Cold): Intake 0.15 – 0.25 mm (0.006 – 0.010 in.) Exhaust 0.25 – 0.35 mm (0.010 – 0.014 in.) BRAKES 13. 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 left before checking the front brake. (a) Check all brake lines and hoses for: • Damage • Wear • Deformation • Cracks • Corrosion • Leaks • Bends • Twists • (b) Check all clamps for tightness and connections for leakage. (c) Check that the hoses and lines are clear of sharp edges, moving parts and the exhaust system. (d) Check that the lines installed in grommets pass through the center of the grommets. MA–30 MAINTENANCE – (1MZ–FE) 14. INSPECT FRONT AND REAR BRAKE PADS AND DISCS (See BR section) (a) Check the thickness of the disc brake pads and check for irregular wear. Minimum pad thickness: 1.0 mm (0.039 in.) HINT: If a squealing or scraping noise comes from the brake durings driving, check the pad wear indicator to see if it is contacting the disc. If so, the disc pad should be replaced. (b) Check the disc for wear or runout. Minimum disc thickness: Front 26.0 mm (1.024 In.) Rear 9.0 mm (0.354 in.) Maximum disc runout: Front 0.05 mm (0.0020 in.) Rear 0.15 mm (0.0059 in.) 15. INSPECT PARKING BRAKE LININGS AND DRUMS (See BR section) (a) Check the lining – to – drum contact condition and lining wear. Minimum lining thickness: 1.0 mm (0.0039 in.) (b) Check the brake drums for scoring or wear. Maximum drum Inside diameter: 171.0 mm (8.732 in.) (c) Clean the brake parts with a damp cloth. NOTICE: Do not use compressed sir to clean the brake parts. MA–31 MAINTENANCE – (1MZ–FE) (d) Settle the parking brake shoes and drum. When per– forming the road test in item 24, do the following: • Drive the vehicle at approx. 50 km/h (30 mph) on a safe, level and dry road. • Center lever type parking brake: With the parking brake release knob pushed in, pull on the lever with 88 N (9 kgf, 20 lbf) of force. • Pedal type parking brake: • Depress the pedal with 147 N (15 kgf, 33 lbf) of force. • Drive the vehicle for approx. 400 m (1 /4 mile) in this condition. • Repeat this procedure 2 or 3 times. Check parking lever travel. CHASSIS 16. INSPECT STEERING LINKAGE (a) Check the steering wheel freeplay. Maximum steering wheel freeplay: 30 mm (1.18 In.) With the vehicle stopped and pointed straight ahead, rock the steering wheel gently back and forth with light finger pressure. (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. 17. INSPECT SRS AIRBAG Driver Airbag: Visually inspect the steering wheel pad (airbag and inflater). • Use the diagnosis check to check if there are abnormalities. • Check that there are no cuts, cracks or noticeable color changes on the surface of the steering wheel pad or in the center groove of the pad. MA–32 MAINTENANCE – (1MZ–FE) Remove the steering wheel pad from the vehicle and check the wiring and steering wheel for damage and corrosion due to rusting, etc. If necessary, replace the steering wheel pad. Front Passenger Airbag: Visually inspect the front passenger airbag assembly (airbag and inflater). • Use the diagnosis check to check if there are abnormalities. • Check that there are no cuts, cracks or noticeable color changes in the front passenger airbag door. • Remove the front passenger airbag assembly from the vehicle and check the wiring and front passenger airbag door for damage and corrosion due to rusting, etc. If necessary, replace the front passenger airbag as– sembly. CAUTION: • For removal and replacement of the steering wheel pad or front passenger airbag assembly, see page RS section and be sure to perform the operation in the correct order. • Before disposing of the steering wheel pad or front passenger airbag assembly the airbag must first be deployed by using SST (See page RS section). 18. INSPECT STEERING GEAR HOUSING OIL Check the steering gear housing for oil leakage. 19. INSPECT DRIVE SHAFT BOOTS Check the drive shaft boots for clamp looseness, grease leakage or damage. MA–33 MAINTENANCE – (1MZ–FE) 20. INSPECT BALL JOINTS 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 m m (7.09–7.87 in.) under the front tires. • Lower the jack untiI there is about half a load onthe front coil springs. Place stands under the vehicle for safety. • Check that the front wheels are in a straight forward position, and block them with chocks. • Using a lever, pry up the end of the lower arm, and check the amount of play. Maximum ball joint vertical play: 0 mm (0 in.) If there is play, replace the ball joint. (b) Check the dust cover for damage. 21. CHECK TRANSAXLE FLUID Visually check the transaxle for fluid leakage. If leakage is found, check for cause and repair. 22. REPLACE TRANSAXLE FLUID A. Replace transaxle (transmission) fluid (a) Using a 10 mm hexagon wrench, remove the drain plug and drain the fluid. (b) Reinstall the drain plug securely. (c) With the engine OFF, add new fluid through the dip– stick tube. Transaxle fluid: ATF DEXRON ΙΙ Drain and refill capacity: 3.5 liters (3.7 US qts, 3.1 Imp. qts) (d) Start the engine and shift the selector into all posi– tions from “P” through “L”, and then shift into “P”. (e) With the engine idling, check the fluid level. Add fluid up to the ”COOL” level on the dipstick. NOTICE: Do not overfill. The transmission and differen– tial are separate units. (f) Recheck the fluid level at the normal operating tem– perature (70 – 80°C (158 – 176°F)) and add as necessary. MA–34 MAINTENANCE – (1MZ–FE) B. Replace differential fluid (a) Remove the filler plug. (b) Using a 10 mm hexagon wrench, remove the drain plug and drain the fluid. (c) Using a 10 mm hexagon wrench, install the drain plug securely. (d) Add new fluid until it begins to run out of the filler hole. (e) Check that the fluid comes to within 5 mm (0.20 in.) of the bottom edge of the filler hole. Fluid type: ATF DEXRON ΙΙ Capacity: 0.95 liters (1.0 US qts, 0.8 Imp. qts) (f) Reinstall the filler plug securely. 23. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY Tighten the following parts: • Front seat mount bolts Torque: 37 N–m (375 kgf–cm, 27 ft–lbf) • Front suspension member –to body mounting bolts Torque: 181 N–m (1,850 kgf–cm, 134 ft–lbf) MA–35 MAINTENANCE – (1MZ–FE) • Rear suspension member–to–body mounting nuts Torque: 51 N–m (520 kgf–cm. 38 ft–lbf) 24. FINAL INSPECTION (a) Check the operation of the body parts: • Hood Auxiliary catch operates properly Hood locks securely when closed • Front and rear doors Door lock operates properly Doors close properly • Luggage compartment door or back door Door lock operates properly • Seats Seat adjusts easily and locks securely in any position Front seat back locks securely in any position Folding–down rear seat backs lock securely (b) Road test: • Check the engine and chassis for abnormal noises. Check that the vehicle does not wander or pull to one side. • Check that the brakes work properly and do not drag. • Perform bedding down of the parking brake shoes and drum. (See page MA–31) (c) Be sure to deliver a clean car and especially check: • Steering wheel • Shift lever knob • All switch knobs • Door handles • Seats MA–36 MAINTENANCE GENERAL MAINTENANCE These are the maintenance and inspection items which are considered to be the owner’s responsibility. They can be perfo– rmed by the owner or they can have them done at a service shop. These items in– clude 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 perform. Items and procedures for general maintanance are as follows: OUTSIDE VEHICLE 1. TIRES (a) Check the pressure with a gauge. Adjust if necessary. (b) Check for cuts, damage or excessive wear. 2. WHEEL NUTS Wheel checking the tires, check the nuts for looseness or for missing nuts. If neces– sary, tighten them. 3. TIRE ROTATION It is recommended that tires be rotated every 12,000 km (7,500 miles). 4. WINDSHIELD WIPER BLADES Check for wear or cracks whenever they do not wipe clean. Replace if necessary. 5. FLUID LEAKS (a) Check underneath for leaking fuel, oil, water or other fluid. (b) If you smell gasoline fumes or notice any leak, have the cause found and corrected. 6. DOORS AND ENGINE HOOD (a) Check that all doors including the trunk lid 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. INSIDE VEHICLE 7. LIGHTS (a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working. (b) Check the headlight aiming. – (1MZ–FE) 8. WARMING LIGHT AND BUZZERS Check that all warning lights and buzzers function properly. 9. HORN Check that it is working. 10. WINDSHIELD GLASS Check for scratches, pits or abrasions. 11. WINDSHIELD WIPER AND WASHER (a) Check operation of the wipers and washer. (b) Check that the wipers do not streak. 12. WINDSHIELD DEFROSTER Check that air comes out from the defrost– er outlet when operating the heater air conditioner at defroster mode. 13. REAR VIEW MIRROR Check that it is mounted securely. 14. SUN VISORS Check that they move freely and are mou nted securely. 15. STEERING WHEEL Check that it has the specified freeplay. Be alert for changes in steering condition, such as hard steering, excessive freeplay or strange noises. 16. SEATS (a) Check that all front seat controls such as seat adjusters, seatback recliner, etc. op– erate smoothly. (b) Check that all latches lock securely in any position. (c) Check that the locks hold securely in any latched position. (d) Check that the head restraints move up and down smoothly and that the locks hold securely in any latched position. (e) For folding–down rear seat backs, check that the latches lock securely. 17. SEAT BELTS (a) Check that the seat belt system such as buckles, retractors and anchors operate properly and smoothly. (b) Check that the belt webbing is not cut, frayed, worn or damaged. 18. ACCELERATOR PEDAL Check the pedal for smooth operation and uneven pedal effort or catching. MA–37 MAINTENANCE 19. BRAKE PEDAL (See BR section) (a) Check the pedal for smooth operation. (b) Check that the pedal has the proper re– serve distance and freeplay. (c) Check the brake booster function. 20. BRAKES At a safe place, check that the brakes do not pull to one side when applied. 21. PARKING BRAKE (See BR section) (a) Check that the lever has the proper travel. (b) On a safe incline, check that the vehicle is help securely with only the parking brake applied. 22. AUTOMATIC TRANSMISSION ”PARK” MECHANISM (a) Check the lock release button of the selec– tor lever for proper and smooth operation. (b) On a safe incline, check that the vehicle is help securely with the selector lever in the “P” position and all brakes released. UNDER HOOD 23. WINDSHIELD WASHER FLUID Check that there is sufficient fluid in the tank. 24. ENGINE COOLANT LEVEL Check that the coolant level is between the ”FULL” and ”LOW” lines on the see– through reservoir. 25. 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. 26. BATTERY ELECTROLYTE LEVEL Check that the electrolyte level of all bat– tery cells is between the upper and lower level lines on the case. 27. BRAKE FLUID LEVEL Check that the brake fluid level is near the upper level line on the see–through reser– voir. 28. ENGINE DRIVE BELTS Check all drive belts for fraying, cracks, wear or oiliness. 29. ENGINE OIL LEVEL Check that level on the dipstick with the – (1MZ–FE) engine turned off. 30. POWER STEERING FLUID LEVEL Check the level. The level should be in the “HOT” or “COLD” range depending on the fluid temperature. 31. AUTOMATIC TRANSMISSION FLUID LEVEL (a) Park the vehicle on a level surface. (b) 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–insert the dipstick and check that the fluid level is in the “HOT” range. (d) Perform this check with the fluid at normal driving temperature (70–80
C, 158 – 176
F). HINT: Wait about 30 minutes before che– cking the fluid level after extended driving at high speeds in hot weather, driving in heavy traffic or with a trailer. 32. EXHAUST SYSTEM Visually inspect for cracks, holes or loose supports. If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located and corrected. MA–38 MAINTENANCE SERVICE SPECIFICATIONS SERVICE DATA Drive belt tension Generator New belt Generator Used belt PS pump New belt PS pump Used belt Spark plug Recommended spark plug ND Spark plug Recommended spark plug NGK Spark plug Correct electrode gap Firing order Valve clearance Intake Valve clearance Exhaust Front and rear brake Minimum Pad thickness Disc thickness Front Minimum Disc thickness Rear Minimum Disc runout Front Maximum Disc runout Rear Maximum Parking brake Lining thickness Minimum Drum inside diameter Maximum Front axle and suspension Ball joint vertical play Maximum Steering wheel freeplay Maximum TORQUE SPECIFICATIONS Pert tightened Front seat mount bolts Front suspension member x Body Rear suspension member x Body – (1MZ–FE) MX–1 MANUAL TRANSAXLE – MANUAL TRANSAXLE MX–2 MANUAL TRANSAXLE – DESCRIPTION DESCRIPTION GENERAL • A triple–cone type synchromesh mechanism is used in the 2nd gear to improve the shift feeling characteristics. This helps to reduce the shifting effort. • A reverse synchromesh mechanism is used to suppress gear engagement noise in reverse gear shifting. Type of Transaxle Type of Engine Gear Ratio Differential Gear Ratio Oil Capacity Oil Viscosity Oil Grade 1st gear 2nd gear 3rd gear 4th gear 5th gear Reverse gear MX–3 MANUAL TRANSAXLE – OPERATION OPERATION The illustration below show the engagements of transaxle gears. MX–4 MANUAL TRANSAXLE – PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS) 09308–00010 Oil Seal Puller Input shaft front bearing Output shaft front bearing 09309–12020 5th Driven Gear Replacer 09310–17010 Transaxle Gear Remover & Replacer (09310–07010) Plate (09310–07020) Center Bolt (09310–07030) Set Bolt 09310–35010 Countershaft Bearing Replacer Input shaft front bearing Output shaft front bearing 09316–60010 Transmission & Transfer Bearing Replacer (09316–00010) Replacer Pipe (09316–00040) Replacer ’C’ 09350–32014 TOYOTA Automatic Transmission Tool Set (09351–32120) Overdrive Bearing Replacer (09351–32130) Handle Differential side bearing MX–5 MANUAL TRANSAXLE – PREPARATION (09351–32150) Oil Seal Replacer Differential side bearing Oil seal (Transaxle case side) 09502–10012 Differential Side Bearing Puller 09564–32011 Differential Preload Adaptor 09608–12010 Front Hub & Drive Pinion Bearing Replacer Set (09608–00070) Drive Pinion Rear Bearing Cone Replacer lnput shaft rear bearing 4th drive gear and rear bearing 09608–20012 Front Nub & Drive Pinion Bearing Tool Set (09608–00080) Replacer Input shaft front oil seal Control shaft cover oil seal (09608–03020) Handle (09608–03060) Replacer Differential taper roller bearing outer race 09612–22011 Tilt Handle Bearing Replacer Output shaft rear bearing No.3 clutch hub 09950–00020 Bearing Remover 09950–00030 Bearing Remover Attachment 09950–20017 Universal Puller MX–6 MANUAL TRANSAXLE – PREPARATION RECOMMENDED TOOLS 09025–00010 Small Torque Wrench Differential preload 09031–00030 Pin Punch 09905–00012 Snap Ring No. 1 Expander EQUIPMENT Dial indicator Torque wrench Feeler gauge LUBRICANT Item Manual transaxle oil Capacity 2.6 liters (2.7 US qts, 2.3 Imp.qts) Classification API GL–3, GL–4 or GL–5 SAE 75W–90 SSM (SPECIAL SERVICE MATERIALS) 08826–00090 Seal Packing 1281, THREE BOND 1281 or equivalent (FIPG) Transmission case x Transaxle case Transmission case x Case cover 08833–00080 Adhesive 1344, THREE BOND 1344, LOCTITE 242 or equivalent Straight screw plug Control shaft cover bolt Trouble Noise Oil leakage Hard to shift or will not shift Jumps out of gear MX–20 MX–20 MX–70 MX–20 MX–20 MX–20 MX–20 MX–33, 40 Oil seal (Worn or damaged) O–Ring (Worn or damaged) Control cable (Faulty) Locking ball spring (Damaged) Shift fork (Worn) Gear (Worn or damaged) Bearing (Worn or damaged) Synchronizer ring (Worn or damaged) Shifting key spring (Damaged) – MX–33,40 – MX–20 Parts Nacre Gasket (Damaged) Oil (Level too high) MX–2 See Page Oil (Wrong) Oil (Level low) MANUAL TRANSAXLE TROUBLESHOOTING MX–7 TROUBLESHOOTING Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. MX–8 MANUAL TRANSAXLE – PRECAUTION PRECAUTION When working with FIPG material, you must observe the following. • Using a razor blade and gasket scraper, remove all the old FIPG material from the gasket surfaces. • Thoroughly clean all components to remove all the loose material. • Clean both sealing surfaces with a non–residue solvent. • Apply the FIPG in an approx. 1 mm (0.04 in.) wide bead along the sealing surface. • Parts must be assembled within 10 minutes of application. Otherwise, the FIPG material must be removed and reapplied. MX–9 MANUAL TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION ASSEMBLY REMOVAL AND INSTALLATION Remove and install the parts as shown below. MX–10 MANUAL TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION TRANSAXLE REMOVAL 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch 1: turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE AIR CLEANER CASE ASSEMBLY WITH AIR HOSE 3. REMOVE CRUISE CONTROL ACTUATOR (a) Remove the cruise control actuator cover. (b) Disconnect the connector. (c) Remove the 3 nuts and cruise control actuator with bracket. 4. REMOVE CLUTCH RELEASE CYLINDER AND TUBE CLAMP 5. REMOVE STARTER (a) Disconnect the connector and wire from the starter. (b) Remove the 2 bolts and starter. 6. DISCONNECT BACK–UP LIGHT SWITCH CONNECTOR MX–11 MANUAL TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 7. DISCONNECT WIRES CLAMP 8. REMOVE EARTH CABLES 9. DISCONNECT CONTROL CABLES (a) Remove the clips and washers. (b) Remove the clips from the cables. 10. REMOVE TRANSAXLE MOUNTING THREE BOLTS OF TRANSAXLE CASE UPPER SIDE 11. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR MX–12 MANUAL TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 12. INSTALL ENGINE SUPPORT FIXTURE 13. TIE STEERING GEAR HOUSING TO ENGINE SUPPORT FIXTURE BY CORD OR EQUIVALENT 14. REMOVE FRONT WHEEL 15. RAISE VEHICLE NOTICE: Be sure the vehicle is securely supported. 16. REMOVE UNDER COVERS AND SIDE COVERS 17. DRAIN TRANSAXLE OIL 18. REMOVE DRIVE SHAFT (See page SA–38) 19. DISCONNECT STEERING GEAR HOUSING FROM FRONT SUSPENSION MEMBER (a) Remove the 4 bolts. (b) Remove the stabilizer bar bush bracket. (c) Remove the 2 set bolts and nuts. (d) Disconnect the steering gearbox from the suspension member. HINT: Suspend the steering gear box with cord. 20. REMOVE EXHAUST PIPE (a) Remove the 3 nuts. (b) Remove the 2 bolts and nuts. MX–13 MANUAL TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION (c) Remove 2 bolts and exhaust pipe. 21. REMOVE STIFFENER PLATE Remove the 3 bolts and the stiffener plate. 22. DISCONNECT ENGINE FRONT MOUNTING FROM SUSPENSION MEMBER Remove the 2 bolts and a nut. 23. DISCONNECT ENGINE REAR MOUNTING FROM FRONT SUSPENSION MEMBER (a) Remove the 2 hole plugs. (b) Remove the 3 nut. 24. REMOVE ENGINE LEFT MOUNTING (a) Raise the transaxle and engine slightly with a jack and wooden block in between. (b) Remove the 2 hole plugs and nuts. MX–14 MANUAL TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION (c) Remove the 3 bolts and engine left mounting. 25. DISCONNECT STEERING COOLER PIPE FROM SUSPENSION MEMBER 26. REMOVE FRONT SUSPENSION MEMBER (a) Remove the 2 fender liner set screws. (b) Remove the 2 bolts and 4 nuts. (c) Remove the 4 bolts. (d) Remove the 2 front lower brace, rear lower brace and front suspension member. 27. REMOVE TRANSAXLE (a) Remove the transaxle mounting bolts from the engine. (b) Lower the engine left side and remove the transaxle from the engine. MX–15 MANUAL TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION TRANSAXLE INSTALLATION (See page MX–9) 1. INSTALL TRANSAXLE TO ENGINE Align the input shaft spline with the clutch disc and install the transaxle to the engine. Bolt A Torque: 64 N–m (650 kgf–cm, 47 ft–lbf) Bolt B Torque: 46 N–m (470 kgf–cm, 34 ft–lbf) 2. INSTALL FRONT SUSPENSION MEMBER (a) Install the front suspension member, rear lower brace, front lower brace and 4 bolts. (b) Torque the 4 bolts. Torque: 181 N–m (1,850 kgf–cm, 134 ft–lbf) (c) Install and torque the 2 bolts and 4 nuts. Bolt Torque: 32 N–m (330 kgf–cm, 24 ft–lbf) Nut Torque: 36 N–m (370 kgf–cm, 27 ft–lbf) (d) Install the 2 fender liner set screws. 3. CONNECT STEERING COOLER PIPE TO FRONT SUSPENSION MEMBER 4. INSTALL ENGINE LEFT MOUNTING (a) Install the engine left mounting. (b) Install and torque the 3 bolts. Torque: 52 N–m (530 kgf–cm, 38 ft–lbf) MX–16 MANUAL TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION (c) Install and torque the 2 nuts. Torque: 80 N–m (820 kgf–cm, 59 ft–lbf) (d) Install the 2 hole plugs. 5. CONNECT ENGINE REAR MOUNTING TO FRONT SUSPENSION MEMBER (a) Install and torque the 3 nuts. Torque: 80 N–m (820 kgf–cm, 59 ft–lbf) (b) Install the 2 hole plugs. 6. CONNECT ENGINE FRONT MOUNTING TO FRONT SUSPENSION MEMBER Install and torque the 2 bolts and a nut. Torque: 80 N–m (820 kgf–cm, 59 ft–lbf) 7. INSTALL STIFFENER PLATE Torque: 37 N–m (380 kgf–cm, 27 ft–lbf) 8. CONNECT STEERING GEAR HOUSING TO FRONT SUSPENSION MEMBER (a) Connect the steering gear housing to the front sus– pension member. (b) Install and torque the 2 set bolts and nuts. Torque: 181 N–m (1,850 kgf–cm, 134 ft–lbf) MX–17 MANUAL TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION (c) Install the stabilizer bar bush bracket. (d) Install and torque the 4 bolts. Torque: 19 N–m (195 kgf–cm, 14 ft–lbf) 9. INSTALL DRIVE SHAFT (See page SA–40) 10. INSTALL EXHAUST FRONT PIPE (a) Install the exhaust front pipe. (b) Install and torque the 2 bolts and nuts. Front side Torque: 62 N–m (630 kgf–cm, 46 ft–lbf) Rear side Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) (c) Connect the exhaust front pipe to the front suspen– sion member. (d) Torque the 2 bolts. 11. FILL TRANSAXLE WITH GEAR OIL Oil: Gear oil super (08885–02106) or equivalent Recommended oil oil grade: API GL–3, GL–4 or GL–5 Viscosity: SAE 75 W–90 Above –18
C (0
F) SAE 90 Below –18
C (0
F) SAE 75 W Capacity: 2.6 liters (2.7 US qts, 2.3 Imp.qts) 12. INSTALL UNDER COVERS AND SIDE COVERS 13. INSTALL FRONT WHEEL AND LOWER VEHICLE Torque: 103 N–m (1,050 kgf–cm, 76 ft–lbf) MX–18 MANUAL TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 14. UNTIE STEERING GEAR HOUSING FROM ENGINE SUPPORT FIXTURE 15. REMOVE ENGINE SUPPORT FIXTURE 16. CONNECT VEHICLE SPEED SENSOR CONNECTOR 17. CONNECT CONTROL CABLES (a) Install the clips to the cables (b) Connect the cables to the linkage with washers and clips. 18. INSTALL EARTH CABLES 19. CONNECT WIRE HARNESS CLAMP MX–19 MANUAL TRANSAXLE – ASSEMBLY REMOVAL AND INSTALLATION 20. CONNECT BACK – UP LIGHT SWITCH CONNECTOR 21. INSTALL STARTER (a) Install the starter. (b) Install and torque the 2 bolts. Torque: 39 N–m (400 kgf–cm, 29 ft–lbf) (c) Connect the connector and wire to the starter. 22. INSTALL CLUTCH RELEASE CYLINDER AND TUBE CLAMP Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) 23. INSTALL CRUISE CONTROL ACTUATOR (a) Install the cruise control actuator bracket with the 3 nuts. (b) Connect the connector. (c) Install the cruise control actuator cover. 24. INSTALL AIR CLEANER CASE ASSEMBLY WITH AIR HOSE 25. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 26. INSPECT FRONT WHEEL ALIGNMENT (See page SA–4) 27. PERFORM ROAD TEST Check for abnormal noise and smooth shifting. MX–20 MANUAL TRANSAXLE – COMPONENT PARTS REMOVAL COMPONENT PARTS REMOVAL COMPONENTS MX–21 MANUAL TRANSAXLE – COMPONENT PARTS REMOVAL MX–22 MANUAL TRANSAXLE – COMPONENT PARTS REMOVAL BASIC SUBASSEMBLY SEPARATION (See page MX–20 and MX–21) 1. REMOVE RELEASE FORK, BEARING BACK – UP LIGHT SWITCH AND VEHICLE SPEED SENSOR 2. REMOVE RELEASE BEARING RETAINER 3. REMOVE ENGINE MOUNT BRACKET AND SELECTING BELLCRANK (a) Remove the 3 bolts and engine mount bracket. (b) Remove the 2 bolts and selecting bellcrank. 4. REMOVE TRANSMISSION CASE COVER (a) Remove the 8 bolts. (b) Using a plastic hammer, tap off the transmission case cover. 5. REMOVE LOCK BALL ASSEMBLY AND PLUG (a) Remove the lock ball. MX–23 MANUAL TRANSAXLE – COMPONENT PARTS REMOVAL (b) Using a hexagon wrench, remove the plug. 6. REMOVE SHIFT AND SELECT LEVER ASSEMBLY 7. REMOVE OUTPUT SHAFT LOCK NUT (a) Unstake the nut. (b) Engage the gear double meshing. (c) Remove the lock nut clockwise and remove it. HINT: The lock nut has LH threads. (d) Disengage the gear double meshing. 8. REMOVE NO.3 HUB SLEEVE AND NO.3 SHIFT FORK (a) Remove the No.3 shift fork set bolt. MX–24 MANUAL TRANSAXLE – COMPONENT PARTS REMOVAL (b) Remove the No.3 hub sleeve and No.3 shift fork. 9. REMOVE 5TH DRIVEN GEAR Using SST, remove the 5th driven gear. SST 09950–20017 10. MEASURE 5TH GEAR THRUST CLEARANCE Using a dial indicator, measure the thrust clearance. Standard clearance: 0.20–0.40 mm (0.0079–0.0157 In.) Maximum clearance: 0.45 mm (0.0177 in.) 11. MEASURE 5TH GEAR RADIAL CLEARANCE Using a dial indicator, measure the radial clearance. Standard clearance: 0.009–0.050 m m (0.0004–0.0020 in.) Maximum clearance: 0.07 mm (0.0028 in.) If the clearance exceeds the maximum, replace the gear, needle roller bearing or input shaft. 12. REMOVE NO.3 CLUTCH HUB AND 5TH GEAR (a) Using 2 screwdrivers and a hammer, tap out the snap ring. MX–25 MANUAL TRANSAXLE – COMPONENT PARTS REMOVAL (b) Using SST, remove the No–3 clutch hub with syn– chronizer ring. SST 09310–17010 (09310–07010, 09310–07020. 09310–07030) (c) Remove the 5th gear. 13. REMOVE NEEDLE ROLLER BEARING 14. REMOVE REAR BEARING RETAINER 15. REMOVE BEARING SNAP RINGS Using a snap ring expander, remove the 2 snap rings. HINT: If it is difficult to remove the snap rings, pull up the shafts. 16. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT 17. REMOVE DIFFERENTIAL SIDE BEARING RETAINER AND SHIM MX–26 MANUAL TRANSAXLE – COMPONENT PARTS REMOVAL 18. REMOVE TRANSMISSION CASE (a) Remove the 17 bolts. (b) Using a plastic hammer, tap off the transmission case. 19. REMOVE REVERSE IDLER GEAR AND SHAFT (a) Pull out the shaft. (b) Remove the idler gear and thrust washer. 20. REMOVE REVERSE SHIFT ARM (a) Shift the fork shaft into reverse. (b) Remove the 2 bolts and pull off the reverse shift arm. 21. REMOVE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS, REVERSE SHIFT FORK WITH INTERLOCK PIN, INPUT AND OUTPUT SHAFTS ASSEMBLY Remove the input shaft assembly and output shaft assembly together with the No. 1 fork shaft, shift head and shift forks with the interlock pin from the trans– axle case. 22. REMOVE DIFFERENTIAL CASE ASSEMBLY MX–27 MANUAL TRANSAXLE – COMPONENT PARTS REMOVAL 23. REMOVE MAGNET FROM TRANSAXLE CASE 24. REMOVE NO.2 FORK SHAFT (a) Using a hexagon wrench, remove the straight screw plug. (b) Using a pin punch and hammer, drive out the slotted spring pin. (c) Pull out the shaft. 25. SEPARATE NO.1 FORK SHAFT, NO.1 SHIFT HEAD, NO.1, NO.2 SHIFT FORKS AND REVERSE SHIFT FORK (a) Mount the shift forks to the vise. (b) Using a pin punch and hammer, drive out the slotted spring pin from the No.1 fork shaft. (c) Using a pin punch and hammer, drive out the slotted spring pin from the No. 1 fork shaft as shown in the illustration. MX–28 MANUAL TRANSAXLE – COMPONENT PARTS REMOVAL (d) Separate the No.1 shift fork shaft, No.1 shift head, No.1, No.2 shift forks and reverse shift fork. 26. REMOVE NO.5 SYNCHRONIZER RING WITH KEY SPRING FROM NO.3 CLUTCH HUB (a) Remove the No.5 synchronizer ring with key spring from No.3 clutch hub. (b) Using a screwdriver, remove the snap ring. HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring. (c) Remove the synchronizer rings. MX–29 MANUAL TRANSAXLE – COMPONENT PARTS REMOVAL COMPONENT PARTS INSPECTION 1. INSPECT N0.5 SYNCHRONIZER RINGS (a) Check for wear or damage. (b) Check the braking effect of the synchronizer ring. Turn the middle No.5 synchronizer ring in one direc– tion while pushing it to the outer No.5 synchronizer ring. Check that the ring locks. If the braking effect is insufficient, replace the syn– chronizer ring. 2. INSPECT CLEARANCE OF NO.3 SHIFT FORK AND NO.3 HUB SLEEVE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve. 3. IF NECESSARY, REPLACE INPUT SHAFT FRONT BEARING (a) Remove the bolt and transaxle case receiver. (b) Using SST, pull out the bearing. SST 09308–00010 (c) Using SST, press in a new bearing. SST 09310–35010 MX–30 MANUAL TRANSAXLE – COMPONENT PARTS REMOVAL (d) Install the transaxle case receiver and torque the bolt. Torque: 7.4 N–m (75 kgf–cm, 65 in–lbf) 4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING (a) Remove the bolt and bearing lock plate. (b) Using SST, pull out the bearing. SST 09308–00010 (c) Using SST, press in a new bearing. SST 09310–35010 (d) Install the bearing lock plate and torque the bolt. Torque: 18 N–m (185 kgf–cm, 13 ft–lbf) MX–31 MANUAL TRANSAXLE – COMPONENT PARTS REMOVAL 5. IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL SEAL (a) Using a screwdriver, pry out the oil seal. (b) Using SST, drive in a new oil seal. SST 09608–20012 (09608–00080, 09608–03020) Drive in depth: 0–0.5 mm (0–0.012 in.) (c) Coat the lip of the oil seal with MP grease. 6. IF NECESSARY, REPLACE REVERSE RESTRICT PIN (a) Using a hexagon wrench, remove the straight screw plug. (b) Using a pin punch and hammer, drive out the slotted spring pin. (c) Replace the reverse restrict pin. MX–32 MANUAL TRANSAXLE – COMPONENT PARTS REMOVAL (d) Using a pin punch and hammer, drive in the slotted spring pin. Drive In depth: 13.5 ± 0.5 mm (0.531 t 0.020 in.) (e) Apply sealant to the plug threads. Sealant: Part No.08833 – 00080, THREE BOND 1344, LOC– TITE 242 or equivalent (f) Using a hexagon wrench, install and torque the strai– ght screw plug. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) MX–33 MANUAL TRANSAXLE – INPUT SHAFT INPUT SHAFT COMPONENTS INPUT SHAFT DISASSEMBLY 1. INSPECT 3RD AND 4TH GEAR THRUST CLEAR– ANCE Using a feeler gauge, measure the clearance. Standard clearance: 3rd gear 0.10–0.25 mm (0.0039–0.0098 in.) 4th gear 0.20–0.45 mm (0.0079–0.0177 in.) Maximum clearance: 3rd gear 0.30 mm (0.0118 in.) 4th gear 0.50 mm (0.0197 in.) MX–34 MANUAL TRANSAXLE – INPUT SHAFT 2. INSPECT 3 RD AND 4 TH GEAR RADIAL CLEARANCE Using dial indicator, measure the radial clearance be– tween the gear and shaft. Standard clearance: 0.009–0.053 mm (0.0004–0.0021 in.) Maximum clearance: 0.070 mm (0.0028 in.) If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft. 3. REMOVE SNAP RING Using 2 screwdrivers and a hammer, tap out the snap ring. 4. REMOVE REAR BEARING, 4 TH GEAR, NEEDLE ROLLER BEARINGS, SPACER AND SYNCHRONIZER RING FROM INPUT SHAFT (a) Using SST and a press, remove the 4th gear and rear bearing. SST 09950–00020 (b) Remove the needle roller bearings, spacer and syn– chronizer ring. 5. REMOVE SNAP RING Using a snap ring expander, remove the snap ring. 6. REMOVE NO. 2 HUB SLEEVE ASSEMBLY, 3 RD GEAR SYNCHRONIZER RING AND NEEDLE ROLLERBEARINGS Using SST and a press, remove the No.2 hub sleeve, 3rd gear, synchronizer ring and needle roller bearings. SST 09950–00020 NOTICE: Be careful not to confuse the synchronizer ring for 3rd gear and synchronizer ring for 4th gear. MX–35 MANUAL TRANSAXLE – INPUT SHAFT 7. REMOVE N0.2 HUB SLEEVE, SHIFTING KEYS AND SPRINGS FROM NO.2 CLUTCH HUB Using a screwdriver, remove the 3 shifting keys and 2 springs from the No.2 clutch hub. M%C^t–^ INPUT SHAFT COMPONENTS INSPECTION 1. INSPECT SYNCHRONIZER RINGS (a) Check for wear or damage. (b) Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while push– ing it to the gear cone. Check that the ring locks. If the braking effect is¿insufficient, apply a small amount of fine lapping compound between the syn– chronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone to– gether. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. (c) Check again the braking effect of the synchronizer ring. (d) Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.6 mm (0.024 fn.) HINT: • When replacing either a synchronizer ring or gear, apply a small amount of fine lapping com– pound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together. • When replacing both the synchronizer ring and gear, there is no need to apply any compound or to rub them together. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. MX–36 MANUAL TRANSAXLE – INPUT SHAFT 2. INSPECT CLEARANCE OF N0.2 SHIFT FORK AND HUB SLEEVE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace shift fork or hub sleeve. 3. INSPECT INPUT SHAFT (a) Check the input shaft for wear or damage. (b) Using a micrometer, measure the outer diameter of the input shaft journal surface. Minimum outer diameter: Part A 26.970 mm (1.0618 in.) Part B 32.470 mm (1.2783 in.) Part C 33.090 mm (1.3028 in.) Part D 29.970 mm (1.1799 in.) If the outer diameter is less than the minimum, replace the input shaft. (c) Using a dial indicator, check the shaft runout. Maximum runout: 0.05 mm (0.0020 in.) If the outer diameter exceeds the maximum, replace the input shaft. MX–37 MANUAL TRANSAXLE – INPUT SHAFT INPUT SHAFT ASSEMBLY (See page MX–33) HINT: Coat all of the sliding and rotating surface with gear oil before assembly. 1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE (a) Install the clutch hub and shifting keys to the hub sleeve. (b) Install the shifting key springs under the shifting keys. NOTICE: Install the key springs positioned so that their and gaps are not line. 2. INSTALL 3RD GEAR, NEEDLE ROLLER BEARINGS. SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS– SEMBLY TO INPUT SHAFT (a) Apply gear oil to the needle roller bearings. (b) Place the synchronizer ring (for 3rd gear) on the gear and align the ring slots with the shifting keys. NOTICE: Do not install the synchronizer ring for 4th gear. (c) Using a press, install the 3rd gear and No.2 hub sleeve. 3. INSTALL SNAP RING (a) Select a snap ring that will allow minimum axial play. Mark Thickness mm (in.) (b) Using a snap ring expander, install the snap ring. MX–38 MANUAL TRANSAXLE – INPUT SHAFT 4. INSPECT 3RD GEAR THRUST CLEARANCE Using a feeler gauge, measure the 3rd gear thrust clearance. Standard clearance: 0.10–0.25 mm (0.0039–0.0098 in.) 5. INSTALL SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS, SPACER, 4TH GEAR AND REAR BALL BEARING (a) Apply gear oil to the needle roller bearings. (b) Install the spacer and needle roller bearings. (c) Place the synchronizer ring on the gear. HINT: Align the ring slots with the shifting keys, and the ring projections with the hub slots. (d) Using SST and a press, install the rear ball bearing. SST 09608–12010 (09608–00070) 6. INSTALL SNAP RING (a) Select a snap ring that will allow minimum axial play. Mark Thickness mm (in.) MX–39 MANUAL TRANSAXLE – INPUT SHAFT (b) Using a screwdriver and hammer, tap in the snap ring. 7. INSPECT 4TH GEAR THRUST CLEARANCE Using a feeler gauge, measure 4th gear thrust clear– ance. Standard clearance: 0.20–0.45 mm (0.0079–0.0177 in.) MX–40 MANUAL TRANSAXLE – OUTPUT SHAFT OUTPUT SHAFT COMPONENTS OUTPUT SHAFT DISASSEMBLY 1. INSPECT 1ST AND 2ND GEAR THRUST CLEAR– ANCE Using a feeler gauge, measure the thrust clearance. Standard clearance: 1st gear 0.10–0.29 mm (0.0039–0.0114 in.) 2nd gear 0.20–0.44 mm (0.0079–0.0173 in.) Maximum clearance: 1st gear 0.35 mm (0.0138 in.) 2nd gear 0.50 mm (0.0197 in.) MX–41 MANUAL TRANSAXLE – OUTPUT SHAFT 2. INSPECT 1 ST AND 2 ND GEAR RADIAL CLEARANCE Using dial indicator, measure the radial clearance be– tween the gear and shaft. Standard clearance: 0.009–0–053 m m (0.0004–0.0021 In.) Maximum clearance: 0.070 mm (0.0028 In.) If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft. 3. REMOVE REAR BALL BEARING, 4TH DRIVEN GEAR AND OUTPUT GEAR SPACER (a) Using SST and a press, remove the rear ball bearing and 4th driven gear. SST 09950–00020 (b) Remove the output gear spacer and bait. 4. REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE ROLLER BEARING AND SYNCHRONIZER RING (a) Shift the No. 1 hub sleeve into the 1 st gear. (b) Using SST and a press, remove the 3rd driven gear and 2nd gear. SST 09950–00020 (c) Remove the needle roller bearing and synchronizer rings. 5. REMOVE NO.1 HUB SLEEVE ASSEMBLY, 1ST GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, THRUST WASHER AND LOCKING BALL (a) Using a press, remove the No.1 hub sleeve, 1st gear and synochronizer ring. (b) Remove the needle roller bearing and locking ball. MX–42 MANUAL TRANSAXLE – OUTPUT SHAFT (c) Using a screwdriver and hammer, drive out the thrust washer. 6. REMOVE NO.1 HUB SLEEVE, SHIFTING KEYS AND SPRINGS FROM NO.1 CLUTCH HUB MX–43 MANUAL TRANSAXLE – OUTPUT SHAFT OUTPUT SHAFT COMPONENT PARTS INSPECTION 1. INSPECT 1ST GEAR SYNCHRONIZER RING (a) Check for wear or damage. (b) Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while push– ing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, apply a small amount of fine lapping compound between the syn– chronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. (c) Check again the braking effect of the synchronizer ring. (d) Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end. Minimum clearance: 0.6 mm (0.024 in.) HINT: • When replacing either a synchronizer ring or gear, apply a small amount of fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together. • When replacing both the synchronizer ring and gear, there is no need to apply any compound or to rub them together. NOTICE: Ensure the fine lapping compound is completely washed off after rubbing. 2. INSPECT 2ND GEAR SYNCHRONIZER RING (a) Check for wear or damage. (b) Check the braking effect of the synchronizer direction while pushing it to the gear cone. Check that the ring locks. If the braking effect is insufficient, replace the syn– chronizer ring. MX–44 MANUAL TRANSAXLE – OUTPUT SHAFT (c) Measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 0.7 mm (0.028 in.) If the clearance is less than the limit, replace the synchronizer ring. 3. INSPECT SHIFT FORKS AND HUB SLEEVES CLEAR– ANCE Using a feeler gauge, measure the clearance between the hub sleeve and shift fork. Maximum clearance: 1.0 mm (0.039 in.) If the clearance exceeds the maximum, replace the shift fork or hub sleeve. 4. INSPECT OUTPUT SHAFT (a) Using a micrometer, measure the outer diameter of the output shaft journal surface. Minimum outer diameter: Part A 31.970 mm 11.2587 In.) Part B 37.970 mm (1.4949 In.) Part C 31.990 mm 11.2594 In.) If the outer diameter is less than the minimum, replace the output shaft. (b) Using a dial indicator, check the shaft runout. Maximum runout: 0.05 mm (0.0020 in.) If the runout exceeds the maximum, replace the output shaft. MX–45 MANUAL TRANSAXLE – OUTPUT SHAFT OUTPUT SHAFT ASSEMBLY (See page MX–40) HINT: Coat all of the sliding and rotating surface with gear oil before assembly. 1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE (a) Install the 3 springs and shifting keys to the clutch hub. (b) Install the hub sleeve to the clutch hub. HINT: Direct identification groove of the hub sleeve to front of the transmission. 2. INSTALL THRUST WASHER, 1 ST GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO OUTPUT SHAFT (a) Using SST and a press, install the thrust washer. SST 09316–60010 (09316–00040) (b) Apply gear oil to the needle roller bearing. (c) Place the synchronizer ring on the gear and align the ring slots with the shifting keys. (d) Using a press, install the 1 st gear and No. 1 hub sleeve. 3. INSPECT 1ST GEAR THRUST CLEARANCE Using a feeler gauge, measure the 1st gear thrust clearance. Standard clearance: 0.10–0.29 mm (0.0039–0.0114 in.) MX–46 MANUAL TRANSAXLE – OUTPUT SHAFT 4. INSTALL SYNCHRONIZER RINGS, 2 ND GEAR, NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR (a) Install the ball. (b) Fit the 2nd gear bushing groove securely over the ball when installing the 2nd gear bushing on the shaft. (c) Place the synchronizer rings on the 2nd gear. (d) Apply gear oil to the needle roller bearing and install it. (e) Install the 2nd gear. NOTICE: Align the clutch hub grooves with the projec– tions on the synchronizer ring. (f) Using SST and a press, install the 3rd driven gear. SST 09316–60010 (09316–00010) 5. INSPECT 2ND GEAR THRUST CLEARANCE Using a feeler gauge, measure the 2nd gear thrust clearance. Standard clearance: 0.20–0.44 mm (0.0079–0.0173 in.) MX–47 MANUAL TRANSAXLE – OUTPUT SHAFT 6. INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN GEAR AND RADIAL BALL BEARING (a) Install the outer gear spacer. (b) Using a press, install the 4th driven gear and bearing. 7. INSTALL REAR BEARING Using SST and a press, install the rear bearing. SST 09612–22011 MX–48 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT SHIFT AND SELECT LEVER SHAFT COMPONENTS SHIFT AND SELECT LEVER SHAFT DISASSEMBLY 1. REMOVE CONTROL SHIFT LEVER, DUST BOOT AND CONTROL SHAFT COVER (a) Remove the nut and washer. (b) Remove the lever lock pin. (c) Remove the control shift lever. (d) Remove the dust boot. (e) Remove the control shaft cover. 2. REMOVE SELECT SPRING SEAT NO.2 AND SHIFT INNER LEVER NO.2 (a) Using a screwdriver, pry out the E–ring. MX–49 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT (b) Remove the reverse restrict pin holder, spring and shift inner lever No.2. 3. REMOVE SHIFT INTERLOCK PLATE, SHIFT INNER LEVER NO.1 AND SELECT SPRING SEAT (a) Using a pin punch and hammer, drive out the slotted spring pin. (b) Remove the shift interlock plate, shift inner lever No.1 and select spring seat. 4. REMOVE E – RING FROM SHIFT AND SELECT LEVER SHAFT Using a screwdriver, pry out the E–ring. MX–50 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT SHIFT AND SELECT LEVER SHAFT ASSEMBLY (See page MX–48) 1. APPLY MP GREASE TO PARTS, AS SHOWN 2. IF NECESSARY, REPLACE CONTROL SHAFT COVER OIL SEAL (a) Using a screwdriver, pry out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the shaft cover surface. SST 09608–20012 (09608–00080, 09608–03020) (c) Coat the lip of the oil seal with MP grease. 3. INSTALL E–RING TO SHIFT AND SELECT LEVER SHAFT MX–51 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT 4. INSTALL SELECT SPRING SEAT, SHIFT INNER LEVER NO.1 AND SHIFT INTERLOCK PLATE (a) Install the select spring seat and Spring. (b) Install the shift inner lever No. 1 with the shift interlock plate. HINT: One of the spline teeth of the shift and select lever shaft has been eliminated. Therefore, be certain to correctly align this portion to the matching portions on the parts during assembly. (c) Using a pin punch and hammer, drive in the slotted spring pin. Drive in depth: 23.5 ± 1.0 mm (0.925 ± 0.039 in.) 6. INSTALL SHIFT INNER LEVER NO.2 AND SELECT SPRING SEAT NO.2 (a) Install the shift inner lever No.2, spring and select spring seat No.2. (b) Using a screwdriver and hammer, tap in the E–ring. MX–52 MANUAL TRANSAXLE – SHIFT AND SELECT LEVER SHAFT 6. INSTALL CONTROL SHAFT COVER, DUST BOOT AND CONTROL SHIFT LEVER (a) Install the control shaft cover and dust boot. HINT: Make sure to install the boot in correct direc– tion. Position the air bleed of the boot downward. (b) Install the control shift lever. (c) Install the lever lock pin to the control shift lever. (d) Install the washer and lock nut. Torque: 6.4 N–m (65 kgf–cm, 56 in.–lbf) MX–53 MANUAL TRANSAXLE – DIFFERENTIAL CASE DIFFERENTIAL CASE COMPONENTS DIFFERENTIAL CASE DISASSEMBLY 1. REMOVE SIDE BEARING FROM DIFFERENTIAL CASE (SPEED SENSOR DRIVE GEAR SIDE) (a) Using SST, remove the bearing from drive gear side of the case. SST 09950–00020, 09950–00030 (b) Remove the speed sensor drive gear. 2. REMOVE RING GEAR (a) Place matchmarks on the ring gear and the case. MX–54 MANUAL TRANSAXLE – DIFFERENTIAL CASE (b) Using a chisel and hammer, unstake the lock plates. (c) Remove the 8 bolts and 4 lock plates. (d) Using a copper hammer, tap on the ring gear to remove it from the case. 3. REMOVE SIDE BEARING FROM DIFFERENTIAL CASE (RING GEAR SIDE) Using SST, remove the bearing from ring gear of side of the case. SST 09950–00020, 09950–00030 4. INSPECT SIDE GEAR BACKLASH Using a dial indicator, measure the backlash of one side gear while holding one pinion toward the case. Standard backlash: 0.05–0.20 mm (0.0020–0.0079 In.) If the backlash does not meet specification, install the correct thrust washer to the side gears. 6. DISASSEMBLY DIFFERENTIAL CASE (a) Using a pin punch and hammer, drive out the straight pin. MX–55 MANUAL TRANSAXLE – DIFFERENTIAL CASE (b) Remove the pinion shaft from the case. (c) Remove the 2 pinions and 2 side gears with the 4 thrust washers from each gear. 6. TRANSMISSION CASE SIDE: IF NECESSARY, REPLACE DIFFERENTIAL SIDE BEARING RETAINER OIL SEAL (a) Using SST and a hammer, drive out the oil seal from the retainer. SST 09608–20012 (09608–03020, 09608–03060) (b) Using SST and a hammer, drive in a new oil seal until its surface is flush with the case surface. SST 09350–32014 (09351–32130, 09351–32150) (c) Coat the lip of the oil seal with MP grease. 7. TRANSAXLE CASE SIDE: IF NECESSARY, REPLACE SIDE OIL SEAL (a) Using a screwdriver and hammer, drive out the oil seal. (b) Using SST and a hammer, drive in a new oil seal until its surface is flush with the case surface. SST 09350–32014 (09351–32130, 09351–32150) (c) Coat the lip of oil seal with MP grease. MX–56 MANUAL TRANSAXLE – DIFFERENTIAL CASE 8. TRANSMISSION CASE SIDE: IF NECESSARY, REPLACE SIDE BEARING OUTER RACE (a) Using a brass bar and hammer, drive out the bearing outer race. (b) Install the bearing retainer without an O–ring. (c) Install and torque the bearing retainer bolts. Torque: 18 N–m (185 kgf–cm, 13 ft–lbf) (d) Place the thinnest shim into the case. (e) Using SST and a press, install a new bearing outer race. SST 09608–20012 (09608–03020, 09608–03060) (f) Remove the retainer bolts. (g) Remove the bearing retainer and shim. 9. TRANSAXLE CASE SIDE: IF NECESSARY, REPLACE SIDE BEARING OUTER RACE (a) Using a brass bar and hammer, drive out the bearing outer race and shim. MX–57 MANUAL TRANSAXLE – DIFFERENTIAL CASE (b) Place the shim into the case. (c) Using SST and a press, install a new bearing outer race. SST 09608–20012 (09608–03020, 09608–03060) DIFFERENTIAL CASE ASSEMBLY (See page MX–53) 1. ASSEMBLY DIFFERENTIAL CASE (a) Install the correct thrust washers and side gears. Referring to the table below, select thrust washers which will ensure that the backlash is within specifica– tion. Try to select washers of the same size for both sides. Standard backlash: 0.05–0.20 mm (0.0020–0.0079 in.) Thickness mm (in.) Thickness mm (in.) 0.95 (0.0374) 1.10 (0.0433) 1.00 (0.0394) 1.15 (0.0453) 1.05 (0.0413) 1.20 (0.0472) Install the thrust washers and side gears in the differ– ential case. (b) Install the pinion shaft. (c) Inspect the side gear backlash. Measure the side gear backlash while holding one pinion gear toward the case. Standard backlash: 0.05–0.20 mm (0.0020–0.0079 in.) If the backlash is not within specification, install a thrust washer of different thickness. (d) Using a pin punch and hammer, drive in the straight pin through the case and hole in the pinion shaft. MX–58 MANUAL TRANSAXLE – DIFFERENTIAL CASE (a) Stake the differential case. 2. INSTALL RING GEAR ON DIFFERENTIAL CASE (a) Clean the contact surface of the differential case and the threads of the ring gear and differential case. (b) Heat the ring gear in boiling water. (c) Carefully remove the ring gear from the water. (d) After moisture on the ring gear has completely evapo– rated, quickly install the ring gear to the differential case. HINT: Align the matchmarks on the differential case and contact the ring gear. (e) Temporarily install the 8 bolts and 4 lock plates. NOTICE: The ring gear set bolts should not be torqued until the ring gear has cooled sufficiently. (f) After the ring gear has cooled sufficiently, torque the ring gear set bolts. Torque: 90 N–m (920 kgf–cm, 67 ft–lbf) (g) Using a pin punch and hammer, stake the lock plates. HINT: Stake one claw flush with the flat surface of the bolt. For the claw contacting the protruding portion of the bolt, stake only the tightened side. 3. INSTALL SIDE BEARING TO DIFFERENTIAL CASE (a) Using SST and a press, install the side bearing to the transmission case side. SST 09316–60010 (09316–00010) 09350–32014 (09351–32120) MX–59 MANUAL TRANSAXLE – DIFFERENTIAL CASE (b) Install the speed sensor drive gear to the transaxle case side. (c) Using SST and a press, install the side bearing to the transaxle case side. SST 09316–60010 (09316–00010) 09350–32014 (09351–32120) NOTICE: Install the black cage bearing on the speed sensor drive gear side. 4. ADJUST DIFFERENTIAL CASE SIDE BEARING PRE– LOAD (a) Install the differential to the transaxle case. (b) Install the transmission case. (c) Install and torque the case bolts. Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) (d) Install the shim into the transmission case. (e) Install the bearing retainer without an O–ring. (f) Install and torque the retainer bolts. Torque: 18 N–m (185 kgf–cm, 13 ft–lbf) MX–60 MANUAL TRANSAXLE – DIFFERENTIAL CASE (g) Using SST and torque meter, measure the preload. SST 09564–32011 Preload (at starting): 0.8–1.6 N–m (8–16 kgf–cm,6.9–13.9 in.–lbf) If the preload is not within specification, remove the transmission case side bearing retainer. Select another shim. HINT: The preload will change about 0.3–0.4 N–m (3–4 kgf–cm, 2.6–3.5 in.–lbf) with each shim thick– ness. Mark Thickness mm (in.) Mark Thickness mm (in.) 1.90 (0.0748) 2.40 (0.0945) 1.95 (0.0768) 2.45 (0.0965) 2.00 (0.0787) 2.50 (0.0984) 2.05 (0.0807) 2.55 (0.1004) 2.10 (0.0827) 2.60 (0.1024) 2.15 (0.0846) 2.65 (0.1043) 2.20 (0.0866) 2.70 (0.1063) 2.25 (0.0886) 2.75 (0.1083) 2.30 (0.0906) 2.80 (0.1102) 2.35 (0.0925) (h) Remove the retainer bolts. (i) Remove the bearing retainer and shim. (j) Remove the case bolts. (k) Remove the transmission case. MX–61 MANUAL TRANSAXLE – COMPONENT PARTS INSTALLATION COMPONENT PARTS INSTALLATION BASIC SUBASSEMBLY REASSEMBLY (See page MX–20 and MX–21) HINT: Coat all of the sliding and rotating surface with gear oil before assembly. 1. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD (See step 4 on page MX–59) 2. INSTALL MAGNET TO TRANSAXLE CASE 3. INSTALL DIFFERENTIAL CASE ASSEMBLY 4. . ASSEMBLE NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1 AND NO.2 SHIFT FORKS (a) Assemble the No.1 shift fork shaft, No.1 shift head, No.1 and No.2 shift forks. (b) Mount the shift forks to the vise. (c) Using a pin punch and hammer, drive in the slotted spring pin to the No.1 fork shaft as shown in the figure. MX–62 MANUAL TRANSAXLE – COMPONENT PARTS INSTALLATION (d) Coat the interlock pin with MP grease. (e) Using a screwdriver, install the interlock pin into the reverse shift fork hole. (f) Install the reverse shift fork to the No.1 shift fork shaft. HINT: When installing the reverse shift fork with inter– lock pin to the No.1 shift fork shaft, make sure the interlock pin does not drop out. NOTICE: Be careful not to damage the bushing. (g) Using a pin punch and hammer, drive in the slotted spring pin to the No.1 fork shaft. 5. INSTALL NO.1 SHIFT FORK SHAFT, NO.1 SHIFT HEAD, NO.1, NO.2 SHIFT FORKS, REVERSE SHIFT FORK WITH INTERLOCK PIN, INPUT AND OUTPUT SHAFT ASSEMBLY Install the input and output shaft assembly together with the No.1 fork shaft, shift head and shift forks with the interlock pin to the transaxle case. 6. INSTALL NO.2 FORK SHAFT (a) Install the No.2 fork shaft to the transaxle case thr– ough the reverse shift fork. (b) Using a pin punch and hammer, drive in the slotted spring pin. MX–63 MANUAL TRANSAXLE – COMPONENT PARTS INSTALLATION (c) Apply sealant to the plug threads. Sealant: Part No.08833 – 00080. THREE BOND 1344, LOC– TITE 242 or equivalent (d) Using a hexagon wrench, install the straight screw plug. Torque: 13 N–m (130 k9f¿cm, 9 ft–lbf) 7. INSTALL REVERSE SHIFT ARM (a) Put the reverse shift fork pivot into the reverse shift arm and install the reverse shift arm to the transaxle case. (b) Shift the reverse shift arm into the reverse. (c) Install and torque the 2 bolts. Torque: 18 N–m (185 kgf–cm, 13 ft–lbf) (d) Shift the reverse shift arm to the neutral position. 8. INSTALL REVERSE IDLER GEAR AND SHAFT (a) Install the washer and reverse idler gear to the shaft. (b) Install the reverse idler gear and shaft as shown. 9. INSTALL TRANSMISSION CASE (a) Remove any FIPG material and be careful not to drop oil on the contacting surface of the transaxle case or transmission case. (b) Apply FIPG to the transmission case as shown. FIPG: Part No.08833–00090, THREE BOND 1281 or equi– valent MX–64 MANUAL TRANSAXLE – COMPONENT PARTS INSTALLATION (c) Install and torque the 17 bolts. Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) 10. INSTALL SHIM AND SIDE BEARING RETAINER WITH O–RING (a) Install a new O–ring on the retainer. (b) Instal) the shim and retainer. (c) Apply sealant to the bolt threads. Sealant: Part No.08833–00080, THREE BOND 1344, LOC– TITE 242 or equivalent (d) Install and torque the 6 bolts. Torque: 18 N–m (185 kgf–cm, 13 ft–lbf) 11. INSTALL AND TORQUE REVERSE IDLER GEAR SHAFT LOCK BOLT Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) 12. INSTALL BEARING SNAP RINGS Using a snap ring expander, install the 2 snap rings. HINT: If it is difficult to install the snap ring, pull up the shafts. MX–65 MANUAL TRANSAXLE – COMPONENT PARTS INSTALLATION 13. INSTALL REAR BEARING RETAINER (a) Apply sealant to the bolt threads. Sealant: Part No.08833–00070, THREE BOND 1324 or equi– valent (b) Install and torque the 5 bolts. Torque: 42 N–m (430 kgf–cm, 31 ft–lbf) 14. INSTALL 5TH DRIVEN GEAR Using SST, install the 5th driven gear. SST 09309–12020 15. INSTALL SPACER, NEEDLE ROLLER BEARINGS, 5TH GEAR AND SYNCHRONIZER RING (a) Install the spacer. (b) Apply gear oil to the needle roller bearings. (c) Install the 5th gear with the needle roller bearings and synchronizer ring. 16. INSTALL NO.5 SYNCHRONIZER RINGS WITH KEY SPRING TO NO.3 CLUTCH HUB (a) Assemble the No.5 synchronizer rings. (b) Using a screwdriver, install the snap ring. HINT: Wrap vinyl tape on the screwdriver to prevent damaging the synchronizer ring. (c) Install the No.5 synchronizer rings with key springs to the No.3 clutch hub. HINT: Align the holes of the clutch hub with key spring. MX–66 MANUAL TRANSAXLE – COMPONENT PARTS INSTALLATION 17. INSTALL N0.3 CLUTCH HUB Using SST and a press, install the No.3 clutch hub assembly. SST 09612–22011 NOTICE: Align the holes of the 5th gear and synchronizer ring. 18. INSTALL SHIFTING KEY RETAINER AND SNAP RING (a) Install the retainer. (b) Select a snap ring that will allow minimum axial play. Mark Thickness mm (in.) Mark Thickness mm (in.) 2.20–2.25 (0.0866–0.0886) 2.60–2.65 (0.1024–0.1043) 2.25–2.30 (0.0886–0.0906) 2.65–2.70 (0.1043–0.1063) 2.30–2.35 (0.0906–0.0925) 2.70–2.75 (0.1063–0.1083) 2.35–2.40 (0.0925–0.0945) 2.75–2.80 (0.1083–0.1102) 2.40–2.45 (0.0945–0.0965) 2.80–2.85 (0.1102–0.1122) 2.45–2.50 (0.0965–0.0984) 2.85–2.90 (0.1122–0.1142) 2.50–2.55 (0.0984–0.1004) 2.90–2.95 (0.1142–0.1161) 2.55–2.60 (0.1004–0.1024) (c) Using a screwdriver and hammer, tap in the snap ring. 19. INSPECT 6TH GEAR THRUST CLEARANCE Using a dial indicator, measure the thrust clearance. Standard clearance: 0.20–0.40 mm (0.0079–0.0157 in.) MX–67 MANUAL TRANSAXLE – COMPONENT PARTS INSTALLATION 20. INSTALL NO. 3 HUB SLEEVE WITH NO. 3 SHIFT FORK (a) Install No.3 hub sleeve with No.3 shift fork to the No.3 clutch hub. (b) Install and torque the set bolt. Torque: 18 N–m (185 kgf–cm, 13 ft–lbf) 21. INSTALL OUTPUT SHAFT LOCK NUT (a) Engage the gear double meshing. (b) Install and torque the new lock nut. Torque: 123 N–m (1,250 kgf–cm. 90 ft–lbf) HINT: The lock nut has LH threads. (c) Stake the lock nut. (d) Disengage the gear double meshing. MX–68 MANUAL TRANSAXLE – COMPONENT PARTS INSTALLATION 22. INSTALL SHIFT AND SELECT LEVER ASSEMBLY (a) Apply FIPG to the underside of the flanged portion of the control shaft cover. FIPG: Part No.08826–00090. THREE BOND 1281 or equi– valent (b) Install the shift and select lever assembly and torque the control shaft cover. Torque: 37 N–m (375 kgf–cm, 27 ft–lbf) 23. INSTALL PLUG (a) Apply sealant to plug threads. Sealant: Part No.08833–00080. THREE BOND 1344, LOC– TITE 242 or equivalent (b) Using a hexagon wrench, install and torque the plug. Torque: 23 N–m (230 kgf–cm, 17 ft–lbf) 24. INSTALL LOCK BALL Install and torque the No.1 lock ball. Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) 25. INSTALL TRANSMISSION CASE COVER (a) Remove the FIPG material and be careful not to drop oil on the contacting surface of the transmission case or tranmission case cover. (b) Apply FIPG to the transmission case cover as shown. FIPG: Part No.08826–00090, THREE BOND 1281 or equi– valent (c) Install the transmission case cover. (d) Apply sealant to the bolt threads. Sealant: Part No.08833–00080, THREE BOND 1344, LOC– TITE 242 or equivalent (e) Install and torque the 8 bolts. Torque: 29 N–m (300 kgf–cm, 22 ft–lbf) MX–69 MANUAL TRANSAXLE – COMPONENT PARTS INSTALLATION 26. INSTALL SELECTING BELLCRANK AND ENGINE MOUNT BRACKET (a) Install the selecting bellcrank and 2 bolts. Torque: 37 N–m (380 kgf–cm. 27 ft–lbf) (b) Install the engine mount bracket and torque the 3 bolts. Torque: 52 N–m (530 kgf–cm, 38 ft–lbf) 27. INSTALL RELEASE BEARING RETAINER Install the release bearing retainer and torque the 3 bolts. Torque: 7.4 N–m (75 kgf–cm, 65 in.¿lbf) 28. INSTALL BACK–UP LIGHT SWITCH Torque: 44 N–m 1450 kgf–cm, 33 ft.–lbf 29. INSTALL VEHICLE SPEED SENSOR 30. INSTALL RELEASE FORK AND BEARING (a) Apply molybdenum disulphide lithium base grease to the following parts: • Input shaft spline • Release fork contact surface (b) Apply MP grease to the front surface of the release bearing. MX–70 MANUAL TRANSAXLE – SHIFT LEVER AND CONTROL CABLE SHIFT LEVER AND CONTROL CABLE COMPONENTS MX–71 MANUAL TRANSAXLE SERVICE SPECIFICATIONS SERVICE DATA Input shaft Roller bearing journal diameter Limit 3rd gear journal diameter Limit 4th gear journal diameter Limit 5th gear journal diameter Limit Runout Limit Output shaft Roller bearing journal diameter Limit 1 st gear journal diameter Limit 2nd gear journal diameter Limit Runout Limit Gear thrust clearance 1 st STD Limit Gear thrust clearance 2nd STD Limit Gear thrust clearance 3rd STD Limit Gear thrust clearance 4th STD Limit Gear thrust clearance 5th STD Limit Gear radial clearance 1 st, 2nd, 3rd and 4th STD Limit Gear radial clearance 5th STD Limit Shift fork to hub sleeve clearance Limit Synchronizer ring to gear clearance 1 at, 3rd and 4th Limit – SERVICE SPECIFICATIONS MX–72 MANUAL TRANSAXLE Synchronizer ring to gear clearance 2nd Limit Input shaft snap ring thickness Differential side bearing adjusting shim thickness – SERVICE SPECIFICATIONS MX–73 MANUAL TRANSAXLE Shift lever preload adjusting shim thickness Differential case side bearing preload (at starting) Differential pinion to side gear backlash Differential side gear thrust washer thickness – SERVICE SPECIFICATIONS MX–74 MANUAL TRANSAXLE TORQUE SPECIFICATIONS Part tightened Transmission case x Transaxle case Transmission case x Case cover Transmission case protector Rear bearing retainer Output shaft front bearing lock plate Input shaft oil receiver 5th driven gear lock nut Reverse idler shaft lock bolt Control shaft cover Control shift lever x lever shaft Ring gear x Differential case Selecting bellcrank x Transmission case Reverse shift arm bracket No.3 shift fork x Shift fork shaft Lock ball assembly Plug Filler plug Drain plug Back–up light switch Side bearing retainer Clutch release bearing retainer Straight screw plug (Shift fork shaft) Straight screw plug (Reverse restrict pin) Transaxle x Engine (12mm bolt) Transaxle x Engine (l0 mm bolt) Engine left mounting x Transmission case Engine left mounting x Sub frame Engine front mounting x Sub frame Engine rear mounting x Sub frame Sub frame x Body Lower brace x Body (Bolt) Lower brace x Body (Nut) Exhaust front pipe x Catalytic converter Exhaust front pipe x Exhaust center pipe Stiffener plate x Clutch housing Stiffener plate x Engine Steering gear housing x Sub frame Stabilizer bar bush bracket x Sub frame Starter x Clutch housing Clutch release cylinder x Clutch housing – SERVICE SPECIFICATIONS RS–1 SUPPLEMENTAL RESTRAINT SYSTEM – SUPPLEMENTAL RESTRAINT SYSTEM RS–2 SUPPLEMENTAL RESTRAINT SYSTEM – GENERAL DESCRIPTION GENERAL DESCRIPTION The 1994 CAMRY is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and front passenger airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deployed during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint system, it is possible the SRS may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedure described in the repair manual. 1. Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble codes become the most important source of information when troubleshoot– ing. When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before disconnecting the battery (See page RS–61). 2. Work must be started after 90 seconds from the time the ignition switch turned to the ”LOCK” position and the negative (–) terminal cable is disconnected from the battery. (The supple– mental restraint system is equipped with a back–up power source so that if work is started within 90 seconds of disconnecting the negative (–) terminal cable of the battery, the SRS may be deployed.) When the negative (–) terminal cable is disconnected from the battery, memory of the clock and audio systems will be canceled. So before starting work, make a record of the contents memorized by the audio memory system. When work is finished, reset the audio systems as before and adjust the clock. To avoid erasing the memory of each memory system, never use a back–up power supply from outside the vehicle. 3. Even in cases of a minor collision where the SRS does not deploy, and the front airbag sensors, the steering wheel pad and front passenger airbag assembly should be inspected (See page RS– 17, 29, 43 and 46). 4. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. 5. Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensors during repairs. 6. Never disassemble and repair the front airbag sensors, center airbag sensor assembly or steering wheel pad or front passenger airbag assembly in order to reuse it. 7. If the front airbag sensors, center airbag sensor assembly or steering wheel pad or front passenger airbag assembly have been dropped, or if there are cracks, dents or dents or other defects in the case, bracket or connector, replace them with new ones. 8. Do not expose the front airbag sensors, center airbag sensor assembly, steering wheel pad and front passenger airbag assembly directly to hot air or flames. 9. Use a volt/ohmmeter with high impedance (10 k
/V minimum) of troubleshooting of the electrical circuit. 10. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. 11. After work on the supplemental restraint system is completed, perform the SRS warning light check (See page RS–61). 12. If the vehicle is equipped with a mobile communication system, refer to the precaution in the IN section. RS–3 SUPPLEMENTAL RESTRAINT SYSTEM – GENERAL DESCRIPTION FRONT AIRBAG SENSOR 1. Never reuse the front airbag sensor involved in a collision when the airbag has deployed. (Replace both the left and right airbag sensors.) 2. Install the front airbag sensor with the arrow on the sensor facing toward the front of the vehicle. 3. The front airbag sensor set bolts have been anti–rust treated. When the sensor is removed, always replace the set bolts with new ones. 4. The front airbag sensors is equipped with an electrical connection check mechanism. Be sure to lock this mechanism securely when connecting the connector. If the connector is not securely locked, a malfunction code will be detected by the diagnosis system (See page RS–13). SPIRAL CABLE (in COMBINATION SWITCH) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may result. Refer to page RS –20 of this manual concerning correct steering wheel installation. RS–4 SUPPLEMENTAL RESTRAINT SYSTEM – GENERAL DESCRIPTION STEERING WHEEL PAD (with AIRBAG) 1. When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. In this case, the twin–lock type connector lock lever should be in the locked state and care should be taken to place it so the connector will not be damaged. And do not store a steering wheel pad on top of another one. (Storing the pad with its metallic surface up may lead to a serious accident if the airbag inflates for some reason. 2. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) 3. Grease should not be applied to the steering wheel pad and the pad should not be cleaned with detergents of any kind. 4. Store the steering wheel pad where the ambient temperature below 93
C (200
F), without high humidity and away from electrical noise. 5. When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed on the glove compartment finish plate at the left side of the glove compartment before starting work. 6. When disposing of a vehicle or the steering wheel pad alone, the airbag should be deployed using an SST before disposal (See page RS–23). Perform the operation in a place away from electrical noise. RS–5 SUPPLEMENTAL RESTRAINT SYSTEM – GENERAL DESCRIPTION FRONT PASSENGER AIRBAG ASSEMBLY 1. Always store a removed or new front passenger airbag assembly with the airbag door facing up. Store the airbag assembly with the airbag door facing down could cause a serious accident if the airbag inflates. 2. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) 3. Grease should not be applied to the front passenger airbag and the door should not be cleaned with detergents of any kind. 4. Store the front passenger airbag assembly where the ambient temperature remains below 93
C (200
F), without high humidity and away from electrical noise. 5. When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed on the glove compartment finish plate at the left side of the glove compartment before starting work. 6. When disposing of a vehicle or the front passenger airbag assembly alone, the airbag should be deployed using an SST before disposal (See page RS–36). Perform the operation in a place away from electrical noise. RS–6 SUPPLEMENTAL RESTRAINT SYSTEM – GENERAL DESCRIPTION CENTER AIRBAG SENSOR ASSEMBLY 1. Never. reuse the center airbag sensor assembly involved in a collision when the airbag has deployed. 2. The connectors to the center airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. If the connectors are connected or disconnected while the center airbag sensor assembly is not mounted to the floor, it could cause undesired ignition of the supplemental restraint system. 3. Work must be started after 90 seconds from the time the ignition switch is turned to ”LOCK” position and the negative (–) terminal cable is disconnected from the battery even just loosing the set bolts of center airbag sensor assembly. WIRE HARNESS AND CONNECTOR The SRS wire harness is integrated with the cowl wire harness assembly. The wires for the SRS wire harness are encased in a yellow corrugated tube. All the connectors for the system are also a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken due to an accident etc., repair or replace it as shown on page RS–49. RS–7 SUPPLEMENTAL RESTRAINT SYSTEM – DESCRIPTION DESCRIPTION The SRS (Supplemental Restraint System), together with the seat belt, is designed to help protect the driver. In a collision, the airbag sensor detect the shock, and if the front–to–rear shock is greater than a specified value, an airbag stored in the steering wheel pad and front passenger airbag assembly are inflated instantaneously. These operation help to reduce the shock to the driver and front passenger airbag assembly. LOCATION OF COMPONENTS RS–8 SUPPLEMENTAL RESTRAINT SYSTEM WIRING DIAGRAM – DESCRIPTION RS–9 SUPPLEMENTAL RESTRAINT SYSTEM – DESCRIPTION CENTER AIRBAG SENSOR ASSEMBLY CONNECTORS Connector No. Symbol Terminal Name Electrical Connection Check Mechanism Electrical Connection Check Mechanism Squib(–) (Front Passenger) Squib(+) (Front Passenger) Squib(+) (Driver) Squib(–) (Driver) Ground Ground Diagnosis Front Airbag Sensor RH(+) Front Airbag Sensor RH(–) Front Airbag Sensor LH(–) Front Airbag Sensor LH(+) SRS Warning Light Power Source (AM2 Fuse) Power Source (CIG Fuse) RS–10 SUPPLEMENTAL RESTRAINT SYSTEM – OPERATION OPERATION FUNCTION OF COMPONENTS 1. FRONT AIRBAG SENSOR A front airbag sensor is mounted inside each of the front fenders. The sensor unit is a mechanical type. When the sensor detects deceleration force above a predetermined limit in a collision, the contacts in the sensor make contact, sending a signal to the center airbag sensor assembly. The sensor cannot be dis– assembled. 2. SPIRAL CABLE (in COMBINATION SWITCH) A spiral cable is used as an electrical joint from the vehicle body side to the steering wheel. 3. STEERING WHEEL PAD (with AIRBAG) The inflater and bag of the supplemental restraint system are stored in the steering wheel pad and cannot be disassembled. The inflater contains a squib, ignite charge, gas generant, etc., and inflates the bag in case of a frontal collision. 4. FRONT PASSENGER AIRBAG ASSEMBLY The inflater and bag of the supplemental restraint system are stored in the front passenger airbag as– sembly and cannot be disassernbled. The inflater con– tains a squib, igniter charge, gas generant, etc., and inflates the bag in case of a frontal collision. 5. SRS WARNING LIGHT The SRS warning light is located on the combination meter. It goes on the alert the driver of trouble in the system when a malfunction is detected in the center airbag sensor assembly self – diagnosis. In normal operating condition when the ignition switch is turned to the ACC or ON position, the light goes on for about 6 seconds and then goes off. RS–11 SUPPLEMENTAL RESTRAINT SYSTEM – OPERATION 6. CENTER AIRBAG SENSOR ASSEMBLY The center airbag sensor assembly is mounted on the floor inside the console box. The center airbag sensor assembly consists of a center airbag sensor, saving sensors, ignition control and drive circuit, diagnosis circuit, etc. It receives signals from the airbag sensors, judges whether the SRS must be activated or not and diagnosis system malfunctions. 7. SRS CONNECTORS A11 connectors in the supplemental restraint system are colored yellow to distinguish them from other connectors. Connectors having special function and specifically designed for SRS are used in the locations shown below to ensure high reliability. These connec– tors use durable gold–plated terminals. No. Item Application Terminal Twin–Lock Mechanism Connectors (1), (2), (3), (4), (5), (6), (7) Airbag Activation Prevention Mechanism Connectors (1), (4), (5), (6) Electrical Connection Check Mechanism Connectors (1), (2), (3) Connector Twin–Lock Mechanism Connectors (4), (5), (6), (7) RS–12 SUPPLEMENTAL RESTRAINT SYSTEM – OPERATION (1) Terminal Twin–Lock Mechanism Each connector has a two–piece construction con– sisting of a housing and a spacer. This design secures the locking of the terminal by two locking devices (the spacer and the lance) to prevent terminals from coming out. (2) Airbag Activation Prevention Mechanism Each connector contains a short spring plate. When the connector is disconnected, The short spring plate automatically connects the power source and ground– ing terminals of the squib. • When Connector is Connected • When Connector is Connected • When Connector is Disconnected • When Connector is Disconnected HINT: The illustration shows connectors S and¿¿. Connector (1) has a short spring plate on the female terminal side, but the operating principle is the same. RS–13 SUPPLEMENTAL RESTRAINT SYSTEM – OPERATION (3) Electrical Connection Check Mechanism This mechanism is designed to electrically check if connectors are connected correctly and completely. The electrical connection check mechanism is desig– ned so that the connection detection pin connects with the diagnosis terminals when the connector hou– sing lock is in the locked condition. • Half Connection • Complete Connection HINT: The illustration shows connector (5) Connector (1) also has the same operating principle. RS–14 SUPPLEMENTAL RESTRAINT SYSTEM – OPERATION (4) Connector Twin–Lock Mechanism With this mechanism connectors (male and female connectors) are locked by two locking devices to increase connection reliability. If the primary lock is incomplete, ribs interfere and prevent the secondary lock. RS–15 SUPPLEMENTAL RESTRAINT SYSTEM – OPERATION When the vehicle is involved in a frontal collision in the hatched area (Fig. 1) and the shock is larger than a predetermined level, the SRS is activated automati– cally. Safing sensors are designed to go on at a sma– ller deceleration rate than the front and center airbag sensors. As illustrated in Fig. 2 below, ignition is caused when current flows to the squib, which hap– pens when a safing sensor and a front airbag sensor and/or the center airbag sensor go on simultaneously. When a deceleration force acts on the sensor, it causes the squib to ignite. Gas is then generated, increasing the pressure inside the bag rapidly. The inflated bag breaks open the steering wheel pad and front passenger airbag assembly. Bag inflation then ends, and the gas is discharged through discharge holes provided behind the bag. The bag becomes deflated as a result. RS–16 SUPPLEMENTAL RESTRAINT SYSTEM – PREPARATION PREPARATION SST (SPECIAL SERVICE TOOLS 09082–00700 SRS Airbag Deployment Tool 09213–31021 Crankshaft Pulley Puller Steering wheel 09843–18020 Diagnosis Check Wire RECOMMENDED TOOLS 09042–00010 Torx Socket T30 Steering wheel pad 09042–00020 Torx Socket T40 Center airbag sensor assembly 09082–00050 TOYOTA Electrical Tester Set EQUIPMENT Torque wrench Bolt Length: 35 mm (1.38 in.) Pitch: 1.0 mm (0.039 in.) Diam.: 6.0 mm (0.236 in.) Airbag disposal Tire Width: 185 mm (7.28 in.) Inner diam.: 360mm (14.17 in.) Airbag disposal Tire with disk wheel Width: 185 mm (7028 in.) Inner diem.: 360 mm (14.17 in.) Airbag disposal Vinyl bag Airbag disposal RS–17 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE STEERING WHEEL PAD AND SPIRAL CABLE INSPECTION ITEMS 1. VEHICLES NOT INVOLVED IN A COLLISION (a) Perform a diagnostic system check (See page RS– 61). (b) Perform a visual check which includes the following items with the steering wheel pad (with airbag) in– stalled in the vehicle. Check for cuts, minute cracks or marked discol– oration of the steering wheel pad top surface and grooved portion. 2. VEHICLES INVOLVED IN A COLLISION IF THE AIRBAG IS NOT DEPLOYED (a) Perform a diagnostic system check (See page RS– 61). (b) Perform a visual check which includes the following items with the steering wheel pad (with airbag) re– moved from the vehicle. • Check for cuts or cracks in, or marked discolora– tion of the steering wheel pad top surface and grooved portion. • Check for cuts and cracks in, or chipping of connectors and wire harness. • Check for deformation of the horn button contact plate of the steering wheel. HINT: • If the horn button contact plate of the steering wheel is deformed, never repair it. Always re– place the steering wheel assembly with a new one. • There should be no interference between the steering wheel pad and the steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is in– stalled on the steering wheel. CAUTION: For removal and installation of the steering wheel pad, see page RS–19. REMOVAL AND INSTAL– LATION’ and be sure to follow the correct procedure. RS–18 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE IF THE AIRBAG IS DEPLOYED (a) Perform a diagnostic system check (See page RS– 61). (b) Perform a visual check which includes the following items with the steering wheel pad (with airbag) re– moved from he vehicle. • Check for deformation of the horn button contact plate of the steering wheel. • Check for damage to the spiral cable connector and wire harness. HINT: • If the horn button contact plate of the steering wheel is deformed, never repair it. Always re– place the steering wheel assembly with a new one. • There should be no interference between the steering wheel pad and the steering wheel, and the clearance should be uniform all the way around when the new steering pad is installed on the steering wheel. REPLACEMENT REQUIREMENTS In the following cases, replace the steering wheel pad, steering wheel or spiral cable. CAUTION: For replacement of the steering wheel pad, see page RS– 19.’STEERING WHEEL PAD AND SPIRAL CABLE REMOVAL AND INSTALLATION’ and be sure to follow the correct procedure. • If the airbag has been deployed. • If the steering wheel pad or spiral cable has been found to be faulty in troubleshooting. • If the steering wheel pad, steering wheel or spiral cable has been found to be faulty during the check in item 1–(b) or 2–(b). • If the steering wheel pad has been dropped. RS–19 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE COMPONENTS STEERING WHEEL PAD AND– SPIRAL CABLE REMOVAL AND INSTALLATION NOTICE: • If the wiring connector of the supplemental re– straint system is disconnected with the ignition switch at ON or ACC, diagnostic trouble codes will be recorded. • Never use SRS parts from another vehicle. When replacing parts, replace with new parts. 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery (See page RS–2). RS–20 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE 2. REMOVE STEERING WHEEL PAD (a) Remove negative terminal (–) from the battery and wait at least 90 seconds. (b) Place the front wheels facing straight ahead. (c) Using a torx wrench, loosen the screws. Produced by TMC: 3 screws Produced by TMM: 2 screws Torx wrench: T30 (Part No. 09042–00010 or locally manufactured tool) (d) Loosen the torx screws until the groove along the screw circumference catches on the screw case. (e) Pull the wheel pad out from the steering wheel and disconnect the airbag connector. NOTICE: When removing the wheel pad, take care not to pull the airbag wire harness. CAUTION: • When storing the wheel pad, keep the upper surface of the pad facing upward (See pages RS–4). • Never disassemble the wheel pad. 3. REMOVE STEERING WHEEL (a) Disconnect the connector. (b) Remove the set nut. (c) Place matchmarks on the steering wheel and main shaft. (d) Using SST, remove the steering wheel. SST 09213–31021 4. REMOVE AND INSTALL SPIRAL CABLE FROM/TO COMBINATION SWITCH NOTICE: Do not disassemble the spiral cable or apply oil to it. 5. CENTER SPIRAL CABLE (a) Check that the front wheels are facing straight ahead. (b) Turn the spiral cable counterclockwise by hand until it becomes harder to turn the cable. (c) Then rotate the spiral cable clockwise about 3 turns to align the red mark. HINT: The spiral cable will rotate about 3 turns to either left or right of the center. RS–21 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE 6. INSTALL STEERING WHEEL (a) Align matchmarks on the steering wheel and main shaft, and install the steering wheel to the main shaft. (b) Install and torque the set nut. Torque: 35 N–m (360 kgf–cm, 26 ft–Ibf) (c) Connect the connector. 7. INSTALL STEERING WHEEL PAD (a) Connect the airbag connector. (b) Install the wheel pad after confirming that the circum– ference groove of the torx screws is caught on the screw case. (c) Using a torx wrench, tighten the screws. Produced by TMC: 3 screws Produced by TMM: 2 screws Torque: 8.8 N–m (90 kgf–cm. 78 in.–lbf) NOTICE: • Make sure the wheel pad is installed to the specified torque. • If the wheel pad has been dropped, or there are cracks, dents or other defects in the case or connec– tor, replace the wheel pad with a now one. • When installing the wheel pad, take care that the wirings do not interfere with other parts and are not pinched between other parts. 8. CHECK STEERING WHEEL CENTER POINT 9. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY RS–22 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE STEERING WHEEL PAD (WITH AIRBAG) DISPOSAL When scrapping vehicles equipped with a supplemen– tal restraint system or disposing of a steering wheel pad (with airbag), always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC.. Never dispose of a steering wheel pad which has an undeployed airbag. When disposing of a steering wheel pad with an airbag deployed in a collision, follow the same proce– dure given under ”When Scrapping Vehicle, part 5, DISPOSAL OF STEERING WHEEL PAD (WITH AIRBAG)”. PRECAUTIONS FOR AIRBAG DEPLOYMENT • The airbag produces a sizeable exploding sound when it deploys, so perform the operation out– of–doors and where it will not create a nuisance to nearby residents. • When deploying the airbag, always use the speci– fied SST; SRS AIRBAG DEPLOYMENT TOOL (SST 09082 –00700). Perform the operation in a place away from electrical noise. • When deploying an airbag, perform the operation from at least 10 m (33 ft) away from the steering wheel pad. • The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a steering wheel pad with deployed airbag. • Always wash your hands with water after com– pleting the operation. • Do not apply water, etc. to a steering wheel pad with deployed airbag. RS–23 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE When scrapping vehicle HINT: Have a battery ready as the power source to deploy the airbag. 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery (See page RS–2). 2. CONFIRM FUNCTIONING OF SST (See page RS–28) SST 09082–00700 3. INSTALL SST CAUTION: Check that there is no looseness in the steer– ing wheel and steering wheel pad. (a) Remove the No.1 under cover. (b) Disconnect the airbag connector of the spiral cable. (c) Connect the SST connector to the airbag connector of the spiral cable. SST 08082–00700 (d) Move the SST to at least 10 m (33 ft) from the front of the vehicle. (e) Close all the doors and windows of the vehicle. NOTICE: Take care not to damage the SST wire harness. (f) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. RS–24 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE 4. DEPLOY AIRBAG (a) Confirm that no–one is inside the vehicle or within 10 m (33 ft) of the vehicle. (b) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. 5. DISPOSAL OF STEERING WHEEL PAD (WITH AIRBAG) CAUTION: • The steering wheel pad is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a ste– ering wheel pad with deployed airbag. • Do not apply water, etc. to a steering wheel pad with deployed airbag. • Always wash your hands with water after complet– ing the operation. (a) When scrapping a vehicle, deploy the airbag and scrap the vehicle with the steering wheel pad still installed. (b) When moving a vehicle for scrapping which has a steering wheel pad with deployed airbag, use gloves and safety glasses. When disposing of steering wheel pad only When disposing of the steering wheel pad (with airbag) only, never use the customer’s vehicle to deploy the airbag. Remove the steering wheel pad from the vehicle and be sure to follow the procedure given below when deploying the airbag. HINT: Have a battery ready as the power source deploy the airbag. 1. REMOVE STEERING WHEEL PAD (Seepage RS–20) CAUTION: • When removing the steering wheel pad (with airbag), work must be started after 90 seconds from the time the Ignition switch is turned to the LOCK position and the negative (–) terminal cable is dis– connected from the battery. • When storing the steering wheel pad, keep the upper surface of the pad facing upward. RS–25 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE 2. REMOVE STEERING WHEEL PAD CONNECTOR Remove the connector on the steering wheel pad rear surface from the inflater cover. 3. FIX STEERING WHEEL PAD TO DISC WHEEL WITH TIRE (a) Install bolts with washer in the 3 bolt holes in the steering wheel pad. Bolt: L 35.0 mm (1.4 in.) M 6.0 mm Pitch 1.0 mm NOTICE: Tighten the bolts by hand until the bolts become difficult to turn. Do not tighten the bolts too much. (b) Using a service–purpose wire harness for vehicle tie down the steering wheel pad to the disc wheel. Wire harness: Stripped wire harness section 1.25 mm2 or more (0.002 in2 or more) HINT: To calculate the square of the stripped wire harness section Square = 3.14 x (Diameter)2 divided by 4 CAUTION: If a wire harness which is too thin or some other thing is used to tie down the steering wheel pad it may be snapped by the chock when the airbag is deplo– yed, this is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 mm2 (0.002 in2.). (1) Using 3 wire harnesses, wrap the wire harnesses at least 2 times each around the bolts installed on the left and right sides of the steering wheel pad. CAUTION: Tightly wind the wire harness around the bolts so that there is no slack. If there is slackness in the wire harness, the steering wheel pad may come loose due to the shock when the airbag is deployed, this is highly dangerous. RS–26 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE (2) Face the upper surface of the steering wheel pad upward. Separately tie the left and right sides of the steering wheel pad to the disc wheel through the hub nut holes. Position the steering wheel pad connector so that it hangs downward through a hub hole in the disc wheel. CAUTION: • Make sure that the wire harness is tight. It is very dangerous if looseness in the wire harness results in the steering wheel pad coming free through the shock of the airbag deploying. • Always tie down the steering wheel pad with the pad side facing upward. It is very dangerous if the steering wheel pad is tied down with the metal surface facing upward as the wire harness will be cut by the shock of the airbag deploying and the steering wheel pad will be thrown into the air. HINT: The disc wheel will be marked by airbag deploy– ment, so use a redundant disc wheel. 4. CONFIRM FUNCTIONING OF SST (See page RS–28) SST 09082–00070 5. INSTALL SST CAUTION: Place the disc wheel on level ground. (a) Connect the SST connector to the steering wheel pad connector. SST 09082–00700 NOTICE: To avoid damaging the SST connector and wire harness, do not lock the secondary lock of the twin lock. Also provide some slack for the SST wire harness inside the disc wheel. (b) Move the SST to at least 10 m (33 ft) away from the steering wheel pad tied down on the disc wheel. 6. COVER STEERING WHEEL PAD WITH CARDBOARD BOX OR TIRES (Covering Method Using Cardboard Box) RS–27 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE Cover the steering wheel pad with the cardboard box and weigh the cardboard box down in four places with a at least 196 N (20 kgf. 44 lbf). Size of cardboard box: Must exceed the following dimensions x= 460 mm (18.11 in.) When dimension y of the cardboard box exceeds the diameter of the disc wheel with tire the steering wheel pad is tied to– x = 460 mm (18.11 in.) + width of tire y = 650 mm (25.59 in.) NOTICE: It a cardboard box smaller than the size speci– fied is used, the cardboard box will be broken by the shock of the airbag deployment. (Covering Method Using Tires) Place at least three tires without disc wheel on top of the disc wheel with tire to which with tire to which the steering wheel pad is tied. Tire size: Must exceed the following dimensions– Width 185 mm (7.28 in.) Inner diam 360 mm (14.17 in.) CAUTION: Do not use tires with disc wheels. NOTICE: The tires by marked by the airbag deployment, so use redundant tires. 7. AIRBAG DEPLOYMENT (a) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. (b) Confirm that no–one is within 10 m (33 ft) of the disc wheel the steering wheel pad is tied to. (c) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. RS–28 SUPPLEMENTAL RESTRAINT SYSTEM – STEERING WHEEL PAD AND SPIRAL CABLE 8. DISPOSAL OF STEERING WHEEL PAD (WITH AIRBAG) CAUTION: • The steering wheel pad is battery hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a ste– ering wheel pad with deployed airbag. • Do not apply water, etc. to a steering wheel pad with deployed airbag. • Always wash your hands with water after complet– ing the operation. (a) Remove the steering wheel pad from the disc wheel. (b) Place the steering wheel pad in a vinyl bag, tie the end tightly and dispose of it the same way as other general parts. CONFIRM FUNCTIONING OF SST When deploying the airbag, always use the specified SST: SRS AIRBAG DEPLOYMENT TOOL. SST 09082–00700 1. CONNECT SST TO BATTERY Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. HINT: Do not connect the yellow connector which connects with the airbag system. 2. CONFIRM FUNCTIONING OF SST Press the SST activation switch, and confirm the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. RS–29 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY FRONT PASSENGER AIRBAG ASSEMBLY INSPECTION ITEMS 1. VEHICLES NOT INVOLVED IN A COLLISION (a) Perform a diagnostic system check (See page RS– 61). (b) Perform a visual check which includes the following items with the front passenger airbag assembly in– stalled in the vehicle. • Check for cuts, minute cracks or marked discolora– tion of the front passenger airbag door. 2. VEHICLE INVOLVED IN A COLLISION IF THE AIRBAG IS NOT DEPLOYED (a) Perform a diagnostic system check (See page RS– 61). (b) Perform a visual check which includes the following items with the airbag assembly removed from the vehicle. • Check for cuts, cracks in, or marked discoloration of the front passenger aribag door. • Check for cuts, cracks in, or chipping of connectors and wire harness. • Check for deformation of the safety pad and instru– ment panel reinforcement. HINT: • If the safety pad and instrument panel reinforce– ment is deformed, never repair it. Always replace it with a new one. • There should be no interfernce between the safety pad and front passenger airbag door. The clearance should be uniform all the way around when the new airbag assembly is installed on the safety pad. CAUTION: For removal and installation of the airbag assembly, see page RS–31, and be sure to follow the correct procedure. RS–30 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY IF THE AIRBAG IS DEPLOYED (a) Perform a diagnostic system check (See page RS– 61). (b) Perform a visual check which includes the following items with the airbag assembly removed from vehicle. • Check for deformation of the safety pad, instrument panel reinforcement, glove compartment and door. • Check for damage to the connector and wire har– ness. HINT: • If the safety pad, instrument panel reinforcement, connector and wire harness is deformed, never repair it. Always replace it with a new one. • There should be no interference between the safety pad and front passenger airbag door. The clearance should be uniform all the way around when the new aribag assembly is installed on the safety pad. REPLACEMENT REQUIREMENTS In the following case, replace the airbag assembly, instrument panel, instrument panel reinforcement, glove compartment and door. CAUTION: For replacement of the airbag assembly, see page RS–31, and be sure to follow the correct proce– dure. • If the airbag has been deployed. • If the front passenger airbag assembly has been found to be fautly in troubleshooting. • If the front passenger airbag assembly, instru– ment panel, reinforcement, glove compartment or glove compartment door has been found to be fautly during the check in item 1–(b) or 2– (b). • If the front passenger airbag assembly has been dropped. RS–31 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY COMPONENTS RS–32 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY FRONT PASSENGER AIRBAG ASSEMBLY TORQUE SPECIFICATION FRONT PASSENGER AIRBAG ASSEMBLY REMOVAL AND INSTALLATION NOTICE: Never use airbag parts from another vehicle. When replacing parts, replace with new parts. 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 second from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery (See page RS–2). 2. DISCONNECT FRONT PASSENGER AIRBAG CON– NECTOR (a) Remove negative (–) terminal from the battery and wait at least 90 seconds. (b) Remove the glove compartment door finish plate inside the glove compartment. 3. DISCONNECT AIRBAG CONNECTER Disconnect the airbag connector. NOTICE: When disconnecting the front passenger airbag connector, take care not to pull the airbag wire harness. RS–33 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY 4. REMOVE AND DISCONNECT FOLLOWING PARTS: • Remove steering wheel pad (See page RS–20) • Remove steering wheel (See page RS–20) (See page BO –108) • Remove under cover No.2 • Remove instrument lower panel • Remove compartment panel • Remove compartment door • Remove combination switch • Remove center cluster finish panel • Remove radio • Remove cluster finish panel • Remove heater control panel 5. REMOVE FRONT PASSENGER AIRBAG (a) Remove the RH side installation bolt. (b) Remove the 5 bolts. (c) Remove the front passenger airbag assembly. CAUTION: • Do not store the front passenger airbag assembly with the airbag door facing down. • Never disassembly the front passenger airbag assembly. 6. INSTALL AIRBAG DOOR AND FRONT PASSENGER AIRBAG ASSEMBLY (W/O AIRBAG DOOR) CAUTION: Make sure to replace the new airbag door and the new airbag assembly (w/o Airbag door) in combina– tion, no alone. (a) Install the airbag door with the 3 bolts. Torque: 8.0 N–m (80 kgf–cm, 89in.–lbf) RS–34 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY (b) Using a reveter, install the 2 new rivet. 6. INSTALL FRONT PASSENGER AIRBAG ASSEMBLY (a) Install the front passenger airbag assembly with the 6 bolts. (b) To instrument panel reinforcement. Diameter = 8 mm (0.32 in.) Torque: 20 N–m (210 kgf–cm, 15 ft–Ibf) To instrument panel Diameter = 6 mm (0.24 in.) Torque: 8.0 N–m (80 kgf–cm, 69 in.–Ibf) NOTICE: • Make sure the front passenger airbag assembly is installed to the specified torque. • If the front passenger airbag assembly has been dropped, or there are cracks, dents or other defects in the case or connector, replace the front passen– ger airbag assembly with a new one. • When installing the front passenger airbag assem– bly, take care that the wiring do not interfere with other parts and are not pinched between other parts. 7. INSTALL FOLLOWING PARTS REMOVAL SE– QUENCE IN REVERSE • Steering wheel Torque: 35 N–m (360 kgf–cm, 26 ft–Ibf) HINT: When installing the glove compartment, pull the airbag wire harness out from the glove compartment opening hole. NOTICE: Do not pull the airbag wire harnesses too stron– gly 8. CONNECT AIRBAG CONNECTOR (a) Connect the airbag connector. (b) Put the connector on the glove compartment door finish plate. (c) Install the glove compartment door finish plate to the glove compartment. 9. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY RS–35 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY FRONT PASSENGER AIRBAG ASSEMBLY DISPOSAL When scrapping vehicles equipped with an supple– mental restraint system or disposing of a front pas– senger airbag assembly, always first deploy the airbag in accordance with the procedure described below. If any abnormality occurs with the airbag deployment, contact the SERVICE DEPT. of TOYOTA MOTOR SALES, U.S.A., INC.. Never dispose of a front passenger airbag assembly which has an undeployed airbag. When disposing of a front passenger airbag assembly with an airbag deployed in a collision, follow the same procedure given under ”WHEN SCRAPPING THE VE– HICLE, part 5, DISPOSAL OF FRONT PASSENGER AIRBAG ASSEMBLY”. PRECAUTIONS FOR AIRBAG DEPLOYMENT • The airbag produces a sizeable exploding sound when it deploys, so perform the operation out– of–doors and where it will not create a nuisance to nearby residents. • When deploying the airbag, always use the speci– fied SST: SRS AIRBAG DEPLOYMENT TOOL (SST 09082–00700). Perform the operation in a place away from electrical noise. • When deploying an airbag, perform the operation from at least 10 m (33 ft) away from the front passenger airbag assembly. • The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front passenger airbag assembly with deployed airbag. • Always wash your hands with water after com– pleting the operation. • Do not apply water, etc., to a front passenger airbag assembly deployed airbag. RS–36 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY When scrapping vehicle HINT: Have a battery ready as the power source to deploy the airbag. 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM THE BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery (See page RS–2). 2. CONFIRM FUNCTIONING OF SST (See page RS–42) SST 09082–00700 3. DISCONNECT CONNECTOR CAUTION: Check that there is no looseness in the front passenger airbag assembly. (a) Remove the glove compartment door finish plate inside the glove compartment. (b) Disconnect the center airbag sensor assembly con– nector from the wiring harness connector. 4. INSTALL SST (a) Connect the SST connector to the airbag connector and lock the secondary lock of the twin lock. SST 09082–00700 RS–37 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY (b) Move the SST to at least 10 m (33 ft) from the front of the vehicle. (c) close all the doors and windows of the vehicle. NOTICE: Take care not change the SST wire harness. (d) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. 6. DEPLOY AIRBAG (a) Confirm that no–one is inside the vehicle or within 10 m (33 ft) of the vehicle. (b) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. 6. DISPOSAL OF FRONT PASSENGER AIRBAG AS– SEMBLY NOTICE: • The front passenger airbag assembly is very out not when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front passenger airbag assembly with deployed airbag. • Do not apply water, etc., to a front passenger airbag asssembly with deployed airbag. • Always wash your hands with water after complet– ing the operation. When scrapping a vehicle, deploy the airbag and scrap the vehicle with the front passenger airbag assembly still installed. RS–38 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY When disposing of front passenger airbag assembly only When disposing of the front passenger airbag assem– bly (w/ airbag) only, never use the customer’s vehicle to deploy the airbag. Remove the front passenger airbag assembly from the vehicle and be sure to follow the procedure given below when diploying the airbag. HINT: Have a battery ready as the power source to deploy the airbag. 1. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY CAUTION: • When removing the front passenger airbag assem– bly, work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is dis– connected from the battery (See page RS–2). • Store the front passenger airbag assembly with the airbag door facing up. 2. FIX FRONT PASSENGER AIRBAG ASSEMBLY TO TIRE (a) Install bolts with washers in the 2 bolt holes in the front passenger airbag assembly. Bolt: L 35.0 mm (1.4 in.) M 6.0 m m Pitch 1.0 mm NOTICE: Tighten the bolts by hand until the bolts become difficult to turn. Do not tighten the bolts too much. RS–39 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY (b) Using a service–purpose wire harness for vehicle, tie down the front passenger airbag assembly to the tire. Wire harness–. Stripped wire harness section 1.25 mm2 or more (0.002 in2 or more). HINT: To calculate the square of the stripped wire harness section – Square = 3.14 x (Diarneter)2 divided by 4 CAUTION: If a wire harness which is too thin or some other thing is used to tie down the front passenger airbag assembly, it may be snapped by the shock when the airbag is deployed, this is highly dangerous. Always use a wire harness for vehicle use which is at least 1.25 mm2 (0.002 in 2). (1) Using 3 wire harness, wrap the wire harnesses at least 2 times each around the bolts installed on the left and right side of the front passenger airbag assembly. CAUTION: Tightly wind the wire harness around the bolts so that there is o slack. lf there is slackness in the wire harness, the front passenger airbag assembly may come loose due to the shock when the airbag is deployed, this is highly dangerous. (2) Position the front passenger airbag assembly inside the tire with the airbag door facing inside. Tie the wire harness to the tire. Tire size: Must exceed the following dimensions Width 185 mm (7.28 in.) Inner diameter 360 mm (14.17 in.) CAUTION: • Make sure the wire harness is tight. It is very dan– gerous if a loose wire harness results in the front passenger airbag assembly coming free due to the shock of the airbag deploying. • Always tie down the front passenger airbag assem– bly with the airbag door facing inside. NOTICE: The tire will be marked by the airbag deploy– ment, so use a redundant tire. RS–40 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY 3. CONFIRM FUNCTIONING OF SST (See page RS–42) SST 09082–00700 4. PLACE TIRES (a) Place at least 2 tires under the tire to which the front passenger airbag assembly is tied. (b) Place at least 2 tires over the tire to which the front passenger airbag assembly is tied. The top tire should have the wheel installed. (c) Tie the tires together by 2 wire harnesses. CAUTION: Make sure that the wire harnesses are tight. It is very dangerous if loose wire harnesses result in the tires coming free due to the shock of the airbag deploy– ing. HINT: Place the SST connect and wire harness inside tires. Provide at least a meter 1 m (3 ft) of slack for the wire harness. 5. INSTALL SST (a) Connect the front passenger airbag assembly connec– tor and lock the secondary lock of the twin lock. (b) Connect the SST connector and lock the secondary lock of the twin lock. SST 09082–00700 6. AIRBAG DEPLOYMENT (a) Connect the SST red clip to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. (b) Confirm that no–one is within 10 m (33 ft) of the tire the front passenger airbag assembly is tied to. (c) Press the SST activation switch and deploy the airbag. HINT: The airbag deploys simultaneously as the LED of the SST activation switch lights up. RS–41 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY 7. DISPOSAL OF FRONT PASSENGER AIRBAG AS– SEMBLY CAUTION: • The front passenger airbag assembly is very hot when the airbag is deployed, so leave it alone for at least 30 minutes after deployment. • Use gloves and safety glasses when handling a front passenger airbag asssembly with deployed airbag. • Do not apply water, etc., to a front passenger airbag assembly with deployed airbag. • Always wash your hand with water after completing the operation. (a) Remove the front passenger airbag assembly from the tire. (b) Place the front passenger airbag assembly in a vinyl bag, tie the end tightly and dispose of it the same way as other general parts. RS–42 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT PASSENGER AIRBAG ASSEMBLY CONFIRM FUNCTIONING OF SST When deploying the airbag, always use the specified SST: SRS AIRBAG DEPLOYMENT TOOL. SST 09082–00700 1. CONNECT SST TO BATTERY Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (–) terminal. HINT: Do not connect the yellow connector which connects with the supplemental restraint system. 2. CONFIRM FUNCTIONING OF SST Press the SST activation switch, and confirm the LED of the SST activation switch lights up. CAUTION: If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST. RS–43 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR FRONT AIRBAG SENSOR INSPECTION ITEMS 1. VEHICLES NOT INVOLVED IN A COLLISION • Perform a diagnostic system check (See page RS–61). 2. VEHICLES INVOLVED IN A COLLISION (a) Perform a diagnostic system check (See page RS–61). (b) If the front fender of the car or its periphery is dam– aged, perform visual check for damage to the front airbag sensor, which includes the following items even if the airbag was not deployed: • Bracket deformation. • Peeling of paint from the bracket. • Cracks, dents or chips in the case. • Cracks and dents in, or chipping and scratches of the connector. • Peeling off of the label or damage to the series number. Also refer to the body dimension drawings check the dimensions and mounting surface angle of the body area where the front airbag sensors are mounted. (The SRS may malfunction, or may not work, if the mount– ing angle or dimensions of the sensor mount are not correct.) REPLACEMENT REQUIREMENTS In the following cases, replace the front airbag sensor. NOTICE: for replacement of the front airbag sensor, see page RS–45,’FRONT AIRBAG SENSOR REMOVAL AND INSTALLATION’. • If the SRS has been deployed in a collision. (Replace both the left and right airbag sensors.) • If the front airbag sensor has been found to be faulty in troubleshooting. • If the front airbag sensor has been found to be faulty during the check in item 2–(b). • If the front airbag sensor has been dropped. RS–44 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR COMPONENTS FRONT AIRBAG SENSOR REMOVAL AND INSTALLATION NOTICE: • If the wiring connector of the supplemental re– straint system is disconnected with the ignition switch at ON or ACC, diagnostic trouble codes will be recorded. • Never use SRS parts from another vehicle. When replacing parts, replace with now parts. • Never reuse the sensor involved in a collision when the SRS has deployed. • Never repair a sensor in order to reuse it. 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable Is discon– nected from the battery (See page RS–2). RS–45 SUPPLEMENTAL RESTRAINT SYSTEM – FRONT AIRBAG SENSOR 2. REMOVE FENDER LINER 3. REMOVE FRONT AIRBAG SENSOR (a) Disconnect the connector. (b) Remove the bolt and sensor. 4. INSTALL FRONT AIRBAG SENSOR Install the sensor with the arrow on the sensor facing toward the front of the vehicle. Torque: 25 N–m (260 kgf–cm, 19 ft–lbf) NOTICE: • Make sure the sensor is installed to the specified torque. • If the sensor has been dropped, or there are cracks dents or other defects in the case, bracket or con– nector, replace the sensor with a new one. • The sensor set bolts have been anti–rust treated When the sensor is removed, always replace the set bolts with new ones. • After installation, shake the sensor to check that there is no looseness. • The front sensor is equipped with an electrical con– nection check mechanism. Be sure to lock this mech– anism securely when connecting the connector. If the connector is not securely locked, a malfunction code will be detected by the diagnosis system. • Check that the dimensions of the body where the front airbag sensor is installed match those in the body dimension drawings in the BODY section. (The SRS may malfunction, or may not work, if the mounting angle or dimensions of the sensor mount are not correct.) 5. INSTALL FENDER LINER 6. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY RS–46 SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY CENTER AIRBAG SENSOR ASSEMBLY INSPECTION ITEMS 1. VEHICLES NOT INVOLVED IN A COLLISION • Perform a diagnostic system check (See page RS–61). 2. VEHICLES INVOLVED IN A COLLISION IF THE SRS IS NOT DEPLOYED • Perform a diagnostic system check (See page RS–61). IF THE SRS IS DEPLOYED • Replace the center airbag sensor assembly certain– ly. REPLACEMENT REQUIREMENTS In the following cases, replace the center airbag sensor assembly. NOTICE: For replacement of the center airbag sensor assembly, see page RS–47, ’CENTER AIRBAG SENSOR ASSEMBLY REMOVAL AND INSTALLATION”. • If the SRS has been deployed in a collision. • If the center airbag sensor assembly has been found to be faulty in troubleshooting. • If the center airbag sensor assembly has been dropped. RS–47 SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY COMPONENTS CENTER AIRBAG SENSOR ASSEMBLY REMOVAL AND INSTALLATION NOTICE: • Do not open the cover or the case of the ECU and various computers unless absolutely necessary. (If the IC terminals are touched, the IC may be destr– oyed by static electricity.) • Never use SRS parts from another vehicle. When replacing parts, replace with new parts. • Never reuse the center airbag sensor assembly in– volved in a collision when the airbag has deployed. • Never repair a sensor in order to reuse it. 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery (See page RS–2). RS–48 SUPPLEMENTAL RESTRAINT SYSTEM – CENTER AIRBAG SENSOR ASSEMBLY 2. REMOVE AND INSTALL CENTER AIRBAG SENSOR ASSEMBLY (a) Using a torx wrench, loosen and tighten the 3 screws. Torx wrench: T40 (Part No. 09042–00020 or locally manufactured tool) (b) Disconnect and connect connector. NOTICE: Removal and installation of the connector is done with the sensor assembly installed. (c) Using a torx wrench, tighten the 3 screws. Torx wrench: T40 (Part No. 09042–00020 or locally manufactured tool) Torque: 20 N–m (200 kgf–cm, 14 ft–lbf) NOTICE: • Make sure the sensor assembly is installed to the specified torque. • If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, brack– et or connector, replace the sensor assembly with a new one. • When installing the sensor assembly, take care that the airbag wiring does not interfere with other parts and is not pinched between other parts. • After installation, shake the sensor assembly to check that there is no looseness. 3. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY RS–49 SUPPLEMENTAL RESTRAINT SYSTEM – WIRE HARNESS AND CONNECTOR WIRE HARNESS AND CONNECTOR HINT: The SRS wire harness is integrated with the cowl wire harness assembly and floor wire harness assembly. The wires for the SRS wire harness are encased in a yellow corrugated tube and all the connectors in the system are a standard yellow color. INSPECTION ITEMS 1. VEHICLES NOT INVOLVED IN A COLLISION • Perform a diagnostic system check (See page RS–61). 2. VEHICLES INVOLVED IN A COLLISION (a) Perform a diagnostic system check (See page RS–61). (b) If there is a break in any of the wires in the SRS wire harness, or if conductors are exposed. (c) In the SRS wire harness connectors are cracked or chipped. RS–50 SUPPLEMENTAL RESTRAINT SYSTEM – WIRE HARNESS AND CONNECTOR REPLACEMENT REQUIREMENTS In the following cases, replace the wire harness or connector. • If any part of the SRS wire harness or any con– nector has been found to be faulty in troublesh– ooting. • If any pant of the SRS wire harness or any con– nector has been found to be faulty during the check in item 2–(b) or (c). NOTICE: If the wire harness used in the SRS is damaged, replace the whole wire harness assembly. When the connector to the front airbag sensors can be repaired alone (when there is no damaged to the wire harness), use the repair wire specially designed for the purpose (See page RS–13). REPAIR WIRE FOR FRONT AIRBAG SENSOR REPLACEMENT Repair wire with 2 pressure–contact sleeves (Part No. 82988–24010) has been prepared for exclusive use in repairing connector damage etc. caused by frontal collision of the vehicle. When repairing the front airbag sensor connector on the wire harness side, always use the special repair wire. NOTICE: Do not replace the connector housing or termi– nal only. AIRBAG REPAIRWIRE REPLACEMENT CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery (See page RS–2). 1. DISCONNECT WIRE HARNESS AT VEHICLE SIDE (a) Remove the cover at the rear of the connect housing and expose the wire harness. (b) Cut the wire harness behind the connector housing. HINT: The operation is performed more easily if the wire harness is left as long as possible. RS–51 SUPPLEMENTAL RESTRAINT SYSTEM – WIRE HARNESS AND CONNECTOR 2. CONNECT FRONT AIRBAG SENSOR WIRE HAR– NESS AT VEHICLE SIDE AND REPAIR WIRE (a) Start stripping at least 8 mm (0.31 in.) to 11 mm (0.43 in.) away from the end of the existing harness at vehicle side and also from the end of the repair wire. NOTICE: Take care not to damage the wire when stripp– ing the wire harness lead. After finishing the operation, visually inspect the wire. If there Is any damaged. per– form the operation again. (b) Overlap the 2 stripped wire ends inside of the pres– sure–contact sleeve as illustrated in the left. HINT: The blue pressure–contact sleeve (Part No. 82999–12020) is available individually. HINT: You might find it easier if you use a miniature screwdriver as a guide as you insert wires into the sleeve. (c) The crimping tool (AMP Part No. 69060) has color marks on it. Place the sleeve in the correct section of the tool according to the color of the sleeve itself. RS–52 SUPPLEMENTAL RESTRAINT SYSTEM – WIRE HARNESS AND CONNECTOR (d) with the center of the sleeve correctly placed be– tween the crimping jaws, squeeze the crimping tool until either end comes into contact at the section marked by ”CLOSE HERE”. HINT: Check to see that the sleeve and wires are still in the correct position before closing the crimping tool ends with steady pressure. (e) Pull the joined wires to either end. Make sure that they are joined firmly by the sleeve. NOTICE: If the joined wire come loose the splice is defec– tive, so replace the sleeve and repeat the procedure. (f) Crimp both ends of the sleeve with the crimping tool at the ”INS” position. 3. PROTECT JOINED SECTION Wrap silicon tape around the joins to protect them from water. HINT: • Before starting the operation, thoroughly wipe dirt and grease off the sections to be joined. • If the adhesive surfaces of two tapes come in contact they will stick together and will not come apart, so do not remove the backing film except when using the tape. • Do not let oil and dust, etc., get on the tape surface. (a) Ready about 100 mm (3.94 in.) of silicon tape (Part No. 08231–00045) and peel oft the film. (b) Stretch the silicon tape until its width is reduced by half. (c) About 10 mm (0.39 in.) from the end of the pressure contact sleeve, wrap the silicon tape around the sleeve 3 or more times while stretching the tape. RS–53 SUPPLEMENTAL RESTRAINT SYSTEM – WIRE HARNESS AND CONNECTOR (d) Wrap the remaining part of sleeve with half of the tape overlapping at each turn. (e) Firmly wrap the tap 2 times or more about 10 mm (0.39 in.) from the other end of the pressure contact sleeve, then wrap the tap back towards the start again and firmly finish winding the tape around the center of the sleeve. (f) Fix the corrugated tube to the wire using silicon tape. (g) After applying the silicon tape, apply vinyl tape on the corrugated tube of repair wire side over to the cor– rugated tube of vehicle wire harness side. RS–54 SUPPLEMENTAL RESTRAINT SYSTEM – MEMO – – WIRE HARNESS AND CONNECTOR RS–55 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING TROUBLESHOOTING RS–56 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING HOW TO PROCEED WITH TROUBLESHOOTING Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trou– ble codes become the most important source of information when troubleshooting. Perform troubleshooting of the supplemental restraint system in accordance with the following procedure: HINT: Do not disconnect the battery negative (–) terminal cable until step [3] , Diagnostic Trouble Code Check and Recording, has been completed. [1] CUSTOMER PROBLEM ANALYSIS Using the CUSTOMER PROBLEM ANALYSIS CHECK SHEET (See page RS–60) for reference, ask the customer in as much detail as possible about the problem. [2] WARNING LIGHT CHECK Check the SRS warning light. If the light remains on, a malfunction is stored in the center airbag sensor, assembly, so proceed to step [3] . If the SRS warning light is not on, a malfunction has occurred in the SRS warning light circuit, so perform troubleshooting for SRS Warning Light System Malfunction. HINT: Code 22 is recorded when a malfunction occurs in the SRS warning light system. If an open malfunction occurs in the SRS warning light system, the SRS warning light does not light up, so that until the malfunction is repaired, the diagnostic trouble codes cannot be confirmed. [3] DIAGNOSTIC TROUBLE CODE CHECK AND RECORDING Check the diagnostic trouble codes and make a note of any malfunction codes which are output. If a normal code is output, an abnormality in the power source circuit may have occurred, so perform troubleshooting for source voltage in step [8] . If code 22 is output, skip steps [4] and [5] and proceed to step [7] . [4] MALFUNCTION CODE CLEARANCE Clear the malfunction code. HINT: The malfunction code output in step [3] indicates that a malfunction has occurred in the circuit designated by the malfunction code, but does not indicate whether the malfunction is still occurring or whether it was in the past. , Accordingly, it is necessary to find out the present condition of the malfunction occurrence by clearing the malfunction code and performing the diagnostic trouble code check again. If this operation is neglected and troubleshooting is performed using only the malfunction code confirmed in step [3] , isolating the problem component becomes difficult and invites mistaken diagnosis. [5] DIAGNOSTIC TROUBLE CODE CHECK AND RECORDING After repeating ignition switch ON–OFF operation (ON: wait 20 secs., OFF: wait 20 secs.) 5 times, check the diagnostic trouble code. If any code is output, the malfunction is still occurring, so proceed to step [7]. Bearing in mind that a malfunction code was registered in step [3] , provided that the normal code is presently output, use the methods described in step [6] to simulate the malfunction. NOTICE: When connecting the battery after clearing the malfunction code, always do it with the ignition switch in ”LOCK” position. When the battery has been reconnected, turn the ignition switch to ACC or ON position after at least 2 seconds have elapsed. If the battery is reconnected with the ignition switch in ACC or ON position, or the ignition switch is turned to ACC or ON within 2 seconds of connecting the battery, it is possible that the diagnosis system will not operate normally. RS–57 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING [6] SYMPTOM SIMULATION [7] DIAGNOSTIC TROUBLE CODE CHART Proceed to the appropriate flow chart in step [8] in accordance with the malfunction code found in step [5] or [6] . [8] CIRCUIT INSPECTION [9] REPAIR Find out if the problem lies in a sensor, actuator or wire harness and connector, and repair the problem. After the problem part is repaired, reinstall the disassembled parts. Do not start work until 90 seconds after the ignition switch is turned to the LOCK position and the negative (–) terminal cable is dis– connected. CAUTION: If incorrect procedure is used, a malfunction may occur in the system or there is the danger that airbag may be accidentally deploy during the repair operation. Carefully read the GENERAL DESCRIPTION (See page RS–2) and the cautions for each operation, perform repairs in the correct order using the correct methods. HINT: The following illustration for the CIRCUIT INSPECTION shows each connector for the SRS squib circuit. RS–58 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING [10] MALFUNCTION CODE CLEARANCE When all the malfunction codes found in steps [5] and [6] have been repaired, clear the malfunction codes. [11] DIAGNOSTIC TROUBLE CODE CHECK After repeating ignition switch ON–OFF operation (ON: wait 20 secs., OFF: wait 20 secs.) 5 times, check the diagnostic trouble codes. If a code is displayed, return to step [7] and troubleshoot the displayed malfunction code. NOTICE: When connecting the battery after clearing the malfunction code, always do it with the ignition switch in ”LOCK” position. When the battery has been reconnected, turn the ignition switch to ACC or ON position after at least 20 seconds have elapsed. If the battery is reconnected with the ignition switch in ACC or ON position, or the ignition switch is turned to ACC or ON within 20 seconds of connecting the battery, it is possible that the diagnosis system will not operate normally. [12] CONFIRMATION TEST Check the warning light again and confirm that all the malfunctions have been repaired. If the warning light indicates and abnormally, repeat the operation again from step [2] . RS–59 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Vehicle Brought to Workshop Customer Problem Analysis RS–60 Warning Lignt Check Does Not Light Up RS–61 Remains ON Diagnostic Trouble Code Check and Recording Normal Code RS–61 Malfunction Code Malfunction Code Clearance RS–65 Diagnostic Trouble Code Check and Recording Normal Code Symptom Simulation Normal Code RS–67 RS–61 Malfunction Code Malfunction Code Diagnostic Trouble Code Matrix Chart RS–69 Circuit Inspection RS–76 Identification of problems Repair Malfunction Code Clearance RS–65 Malfunction Code Diagnostic Trouble Code Check RS–61 Confirmation Test END : Diagnostic steps permitting the use of the TOYOTA hand–held tester. RS–60 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING CUSTOMER PROBLEM ANALYSIS CHECK SHEET RS–61 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSIS INSPECTION SRS warning light check (a) Turn the ignition switch to ACC or ON and check that the SRS warning light lights up. (b) Check that the SRS warning light goes out after approx. 6 seconds. HINT: • When the ignition switch is at ACC or ON and the SRS warning light remains on, the center airbag sensor as– seemly has detected a malfunction code. • If, after approx. 6 seconds have elapsed, the SRS warn– ing light sometimes lights up or the SRS warning light lights up even when the ignition switch is OFF, a short in the SRS warning light circuit can be considered like– ly. Proceed to SRS warning light system (always lit up, when ignition switch LOCK position) on page RS–146. Diagnostic trouble code check Using diagnosis check wire: 1. OUTPUT DIAGNOSTIC TROUBLE CODE (a) Turn the ignition switch to ACC or ON position and wait Approx. 20 seconds. (b) Using SST, connect terminals Te and El of the DLC1 or DLC2. SST 09843 – 18020 NOTICE: Never make a mistake with the terminal connec– tion position as this will cause a malfunction. RS–62 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING 2. READ DIAGNOSTIC TROUBLE CODE Read the 2–digit diagnostic trouble code as indicated by the number of times the SRS warning light blinks. As an example, the blinking patterns, normal, 11 and 31 are as shown on the illustration. • Normal code indication The light will blink 2 times per second. • Malfunction code indication In the event of a malfunction, the light will blink. The number represented by the first blink code output indicates the first digit of a 2–digit diagnostic trouble code. After a 1.5 second pause, the second blink code will indicate the second digit. If there are 2 or more codes, there will be a 2.5 second pause between each. After all the codes have been output, there will be a 4.0 second pause and they will all be repeated. HINT: • In the event of a number of trouble codes, indication will 1st from the smallest numbered code to the larger. • If it does not output a diagnostic trouble code or outputs a diagnostic trouble code without terminal connection, proceed to the Tc terminal circuit inspection on page RS– 127. Using TOYOTA hand–held Tester (a) Hook up the TOYOTA hand–held tester to the DLC1 or DLC2. (b) Read the diagnostic trouble codes by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand–held tester operator’s manual for further details. RS–63 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSTIC TROUBLE CODES DTC No. (Nor– mal) Blink Pattern Diagnosis • System normal • Source voltage drop • Short in squib circuit or front airbag sensor circuit (to ground) Front airbag sensor or malfunction Center airbag sensor assembly malfunction • • • • • 22* Short in squib circuit (to +B) Open in front airbag circuit Short in squib circuit (between D+ wire harness and D– wire harness) Trouble Area SRS Warning Light OFF • • Battery Center airbag sensor assembly • • Steering wheel pad (squib) Front passenger airbag sensor (squib) Front airbag sensor Spiral cable Center airbag sensor assembly Wire harness • • • • • • • • • • • • Steering wheel pad (squib) Front passenger airbag sensor (squib) Front airbag sensor Spiral cable Center airbag sensor assembly Wire harness • Steering wheel pad (squib) Spiral cable Center airbag sensor assembly Wire harness • Open in driver side airbag squib circuit • • • • Steering wheel pad (squib) Spiral cable Center airbag sensor assembly wire harness • Open in front airbag sensor circuit • • • Front airbag sensor Center airbag sensor assembly Wire harness • SRS warning light system malfunction • • • SRS warning light Center airbag sensor assembly Wire harness • Open in center airbag sensor assembly connector malfunction • • Center airbag sensor assembly Wire harness • Center airbag sensor assembly malfunction • Center airbag sensor assembly • Short in passenger airbag squib circuit (between P+ wire harness and P+ wire harness) • • • • Front passenger airbag assembly Wiring harness Center airbag sensor assembly Wire harness • Open in passenger airbag squib circuit • • • • Front passenger airbag assembly Wiring harness Center airbag sensor assembly Wire harness RS–64 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING HINT: • When the SRS warning light remains lit up and the diagnostic trouble code in the normal code, this means a source voltage drop. This malfunction is not stored in memory by the center airbag sensor Assembly and if the power source voltage returns to normal, after approx. 10 seconds the SRS warning light will automatically go out. • Code 22 is recorded when a malfunction occurs in the SRS warning light system. If an open malfunction occurs in the SRS warning light system, the SRS warning light does not light up, so that until the malfunction is repaired, the diagnostic trouble codes (including code 22) cannot be con– firmed. • When 2 or more codes are indicated, the lowest numbered code will appear first. • If a code not listed on the chart is displayed, then the center airbag sensor assembly is faulty. RS–65 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING CLEARING OF DIAGNOSTIC TROUBLE CODE Using diagnosis check wire: (a) Connect service wires to terminals Tc and AB of the check connector. (b) Turn the ignition switch ACC or ON and wait approx. 6 seconds. (c) Starting with the Tc terminal, apply body ground alternate– ly to terminal Tc and terminal AB twice each in cycles of 1.0 ±0.5 seconds. (Confirm that body ground is absolute.) Finally, keep applying body ground to terminal Tc. HINT: When alternately grounding terminals Tc and AB, release ground from one terminal and immediately apply it to the other terminal. This action must be done within the time limits shown below. If you are not within the time limits, repeat the above procedure until you clear the codes. (d) Several seconds after performing the clearing procedure, the SRS warning light will blink in a 50 m sec. cycle to indicate the codes have been cleared. RS–66 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Using TOYOTA hand–held tester (a) Hook up the TOYOTA hand–held tester to the DLC1 or DLC2. (b) Clear the diagnostic trouble codes by following the prompts on the tester screen. HINT: Please refer to the TOYOTA hand–held tester operator’s manual for further details. RS–67 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING SYMPTOM SIMULATION ”Intermittent troubles or problems” are the malfunctions about which the customer has a complaint, but which do not occur and can not be conformed in the workshop. The intermittent problems also include complaints about the SRS warning light going on and off erratically. The self–diagnostic system stores the circuit of the intermittent problem in memory even if the ignition switch is turned off. And, for accurate diagnosis of the problems, ask the customer to obtain information as much as possible following the customer problem analysis check sheet (See page RS–60) and try to reproduce the intermittent problem. The problem simulation methods described below are the effective ways for this nature of problem to pro– duce the problem conditions by applying vibration, heat, and humidity. VIBRATION METHOD: when vibration seems to be the major cause. CONNECTORS Slightly shake the connector vertically and horizontally. (inspection of connectors) (a) Does the wire harness connecting with its cor– responding part have insufficient slack? (b) Are the terminals dirty? (c) Are the terminals making loose contact due to ter– minals spread? WIRE HARNESS Slightly shake the wire harness vertically and horizon– tally. The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thoroughly. PARTS AND SENSORS Apply vibration slightly by a finger to the part or sensor considered to be the problem cause and check if the malfunction will occur. CAUTION: Do not apply vibration to the center airbag sensor assembly. RS–68 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that is likely the cause of the mal– function with a hair dryer or similar object. Check to see if the malfunction will occur. NOTICE: • Do not heat to more than 60
C (140
F) (Tempera– ture limit that the component can be touched with a hand.). • Do not apply heat directly to part in the ECU. WATER SPRINKLING When the malfunction seems to occur on a METHOD: rainy day or in a high–humidity condition. Sprinkle water onto the vehicle and check to see if the malfunction will occur. NOTICE: Never apply water directly onto the electronic components. HINT: • If a vehicle is subject to water leakage, the leaked water may contaminate the ECU. When testing a vehicle with a water leakage problem, special caution must be paid. OTHER: when a malfunction seems to occur when electrical load is excessive. Turn on all electrical loads including the heater blower, headlights, rear window defogger, etc. and check to see if the malfunction will occur. RS–69 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSTIC TROUBLE CODE MATRIX CHART If a malfunction code is displayed during the diagnostic trouble code check, check the circuit listed for that code in the table below (Proceed to the page given for that circuit.). Diagnosis DTC No. (Normal)*1 22*2 Page • Source volatage drop RS–76 • Short in squib circuit or front airbag sensor circuit (to ground) RS–80 • Short in squib circuit or front airbag sensor circuit (to +B) RS–88 • Short in squib circuit (between D+ wire harness and D– wire harness) RS–96 • Open in squib circuit (between D+ wire harness and D– wire harness) RS–104 • Open in front airbag sensor circuit RS–110 • SRS warning light system malfunction RS–116 • Open in center airbag sensor assembly connector malfunction RS–122 • Center airbag sensor assembly malfunction RS–126 • Short in squib circuit (between P+ wire harness and P– wire harness) RS–128 • Open in squib circuit (between P+ wire harness and P– wire harness) RS–134 HINT: *1 When the SRS warning light remains lit up and the diagnostic trouble code is the normal code, this means a source voltage drop. *2 Code 22 is recorded when a malfunction occurs in the SRS warning light system. If an open malfunction occurs in the SRS warning light system, the SRS warning light does not light up, so that until the malfunction is repaired, the diagnostic trouble codes (including code 22) cannot be confirmed. PROBLEM SYMPTOM CHART Proceed with troubleshooting of each circuit in the table below. Problem Symptom Inspection Item Page RS–140 • With the ignition switch at ACC on ON, the SRS warning light does not lights up. • SRS warning light malfunc– tion. • With the ignition switch at ACC or ON, the SRS warning light sometimes lights up after approx. 6 seconds have elapsed. SRS warning light lights up even when ignition switch is in the LOCK position. • SRS Warning light system (Always lit up when ignition switch is LOCK position) Diagnostic trouble code not displayed. Diagnostic trouble code continuously displayed. • • • • Te terminal circuit RS–146 RS–148 RS–70 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING LOCATION OF CONNECTORS Location of Connectors in Engine Compartment 1 MZ–FE 5S–FE RS–71 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING RS–72 SUPPLEMENTAL RESTRAINT SYSTEM Jl6 No. 2 – TROUBLESHOOTING RS–73 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Location of Connectors in Instrument Panel RS–74 SUPPLEMENTAL RESTRAINT SYSTEM JIB No. 1 – TROUBLESHOOTING RS–75 SUPPLEMENTAL RESTRAINT SYSTEM J/B No. 3 – TROUBLESHOOTING RS–76 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING CIRCUIT INSPECTION DTC (Normal) Source Voltage Drop CIRCUIT DESCRIPTION The supplemental restraint system is equipped with a voltage – increase circuit (DC–DC converter) in the center airbag sensor assembly in case the source voltage drops. When the battery voltage drops, the voltage – increase circuit (DC–DC converter) functions to increase the voltage of the supplemental restraint system to normal voltage. The diagnosis system malfunction display for this circuit is different to other circuits – when the SRS warning light remains lit up and the diagnostic trouble code is a normal code, source voltage drop is indicated. Malfunction in this circuit is not recorded in the center airbag sensor assembly, and approx. 10 seconds after the source voltage returns to normal, the SRS warning light automatically goes off. Diagnosis DTC No. (Normal) Source voltage drop. DIAGNOSTIC CHART Preparation. Does SRS warning light turnoff after approx. 10 seconds? YES Check battery and charging system (See CHARGING SYSTEM). Check diagnostic trouble code, and if a malfunction code is output, perform troubleshooting according to malfunction code. If a normal code is output, replace center air– bag sensor assembly. RS–77 SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTIC CHART WIRING DIAGRAM – TROUBLESHOOTING RS–78 SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURES – TROUBLESHOOTING Preparation Check Preparation. (1) Turn ignition switch LOCK. (2) Disconnect battery negative (–) terminal ca– ble, and wait at least 90 seconds. (3) Connect battery negative (–) terminal cable. (4) Disconnect center airbag sensor assembly connector. (5) Turn ignition switch O N. But do not start engine. (6) Measure voltage at IG2 or ACC on connector wire harness side of center airbag sensor as– sembly and operate electric system (defogger, wiper, headlight, heater blower, etc.). Voltage: 6 V – 11.5 V at IG2 and ACC. (7) Turn electric system switch OFF. (8) Turn ignition switch LOCK. (9) Disconnect battery negative (–) terminal ca– ble, and wait at least 90 seconds. (10) Remove voltmeter and connect center airbag sensor assembly connector. (11) Connect battery negative (–) terminal cable. Does SRS warning light turn off? Turn ignition switch ON. Operate electric system checked in check that SRS warning light goes off. YES Check battery and charging system . (5) and Check diagnostic trouble code, and if a malfunc– tion code is output, perform troubleshooting according to malfunction code. If a normal code is output, replace center airbag sensor assembly. RS–79 SUPPLEMENTAL RESTRAINT SYSTEM – MEMO – – TROUBLESHOOTING RS–80 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DTC 11 Short in Squib Circuit or Front Airbag Sensor Circuit (to Ground) CIRCUIT DESCRIPTION The squib circuit consists of the center airbag sensor assembly, spiral cable, steering wheel pad (squib), wire harness connector and front passenger airbag assembly(squib). It causes the airbag to operate when the airbag operation conditions are satisfied. The front airbag sensor detects the deceleration force in a frontal collision and is located in front fender on the left and right sides. For details of the function of each component, see FUNCTION OF COMPONENTS on page RS–10. Diagnostic trouble code 11 is recorded when ground short is detected in the squib circuit or front airbag sensor circuit. DTC No. • • • • • • • Diagnosis Short circuit in squib wire harness (to ground). Squib malfunction. Short circuit in front airbag sensor +S, D+, D–, P+, P–, wire harness (to ground). Front airbag sensor malfunction. Short circuit between +S wire harness and –S wire harness of front airbag sensor. Spiral cable malfunction. Center airbag sensor assembly malfunction. RS–81 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSTIC CHART Preparation. Check front airbag sensor circuit. (Measure resis– tance between terminals +SR and –SR, +SL and –SL of center airbag sensor assembly connector.) Go to step [9] on next page. Check front airbag sensor circuit. (Measure resis– tance between terminals +SR, +SL of center airbag sensor assembly connector and body ground.) Repair or replace harness or connector between front airbag sensor and center airbag sensor assembly (See page RS– 50). Check D squib circuit. (Measure resistance between terminals D+, D– of center airbag assembly con– nector and body ground.) Go to step [10] on next page. Check P squib circuit. (Measure resistance between terminals P+, P– of center airbag assembly con– nector and body ground.) Repair or replace harness or connector between front airbag sensor and center airbag sensor assembly (See page RS– 50). Check center airbag sensor assembly. Replace center airbag sensor assembly. Check D squib. Replace steering wheel pad. Check P squib. Replace front passenger airbag assembly. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. RS–82 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSTIC CHART (Cont’d) Check front airbag sensor. Replace front airbag sensor. Repair or replace harness or connector between front airbag sensor and center airbag sensor assembly (See page RS–50). Check spiral cable. Repair or replace harness or connector between center airbag sensor assembly and spiral cable. WIRING DIAGRAM Repair or replace spiral cable. RS–83 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING INSPECTION PROCEDURE Preparation Check Preparation. (1) Disconnect battery negative (–) terminal cable, and wait at least 90 seconds. (2) Remove steering wheel pad (See page RS– 20). (3) Disconnect connectors of front passenger airbag assembly. (See page RS–29) Store the steering wheel pad with the front surface facing upward. Check front airbag sensor circuit. (Measure resistance between terminals +SR and –SR, +SL and –SL of center airbag sensor assembly connector.) Disconnect center airbag sensor assembly con– nectors. Measure resistance between terminals +SR and –SR, +SL and –SL of harness side connector of center airbag sensor assembly. Resistance: 755 Ω – 885 Ω Go to step RS–84 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check front airbag sensor circuit. (Measure resistance between terminals +SR, +SL of center airbag sensor assembly connector and body ground.) Measure resistance between terminals +SR, +SL of harness side connector of center airbag sensor assembly and body ground. Resistance: 1 M
or higher. Repair or replace harness or connector between front airbag sensor and center airbag sensor assembly (See page RS–50). Check D squib circuit. For the connector (on the spiral cable side) between the spiral cable and steering wheel pad, measure the resistance between D+, D– and body ground. Resistance: 1 M
or higher Go to step RS–85 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check P squib circuit. For the connector (on the wiring harness connector side) between the wiring harness connector and front passenger airbag assembly, measure the re– sistance between P+, P– and body ground. Resistance: 1 M
or higher Repair or replace harness of connector between the center airbag sensor assembly and front passenger airbag assembly. Check center airbag sensor assembly. (1) Connect connectors to center airbag sensor assembly. (2) Using a service wire, connect D+ and D– on spiral cable side of connector between spiral cable and steering wheel pad. (3) Using a service wire, connect P+ and P– on center airbag sensor assembly side of connec– tor between center airbag sensor assembly and front passenger airbag assembly. (4) Connect negative (–) terminal cable to battery, and wait at least 2 seconds. (5) Turn ignition switch ACC or ON, and wait at least 20 seconds. Clear malfunction code (See page RS–65). Turn ignition switch LOCK and wait at least 20 seconds. (1) Turn ignition switch ACC or ON and wait at least 20 seconds. (2) Using SST, connect terminals Tc and El of DLC1 or DLC2. SST 09843–18020 (3) Check diagnostic trouble code. Diagnostic trouble code 11 is not output. Codes other than code 11 may be output at this time, but they are not relevant to this check. Replace center airbag sensor assembly. RS–86 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check D squib. (1) Turn ignition switch LOCK. (2) Disconnect battery negative (–) terminal cable, and wait at least 90 seconds. (3) Connect steering wheel pad (squib) connec– tor. (4) Connect negative (–) terminal cable to battery, and wait at least 2 seconds. (5) Turn ignition switch ACC or ON, and wait at least 20 seconds. Clear malfunction code. Turn ignition switch LOCK, and wait at least 20 seconds. (1) Turn ignition switch ACC or ON, and wait at least 20 seconds. (2) Using SST, connect terminals Tc and El of DLC1 or DLC2. SST 09843–18020 (3) Check diagnostic trouble code. Diagnostic trouble code 11 is not output. Codes other than code 11 may be output at this time, but they are not relevant to this check. Replace steering wheel pad. Check P squib. (1) Turn ignition switch LOCK. (2) Disconnect battery negative (–) terminal cable, and wait at least 90 seconds. (3) Connect front passenger airbag assembly (squib) connector. (4) Disconnect steering wheel pad (squib) con– nector. (5) Connect negative (–) terminal cable to battery, and wait at least 2 seconds. (6) Turn ignition switch ACC or ON, and wait at least 20 seconds. Clear malfunction code. Turn ignition switch LOCK, and wait at least 20 seconds. (1) Turn ignition switch ACC or ON, and wait at least 20 seconds. (2) Using SST, connect terminals Tc and El of DLC1 or DLC2. (3) Check diagnostic trouble code. Diagnostic trouble code 11 is not output. Codes other than code 11 may be output at this time, but they are not relevant to this check. Replace front passenger airbag assembly. RS–87 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Check front airbag sensor. Disconnect front airbag sensor connector. Measure resistance between each terminal of front airbag sensor. Terminal (+)S – (+)A (+)S – (–) S Resistance Below 1 Ω M CI or higher (–)S – (–) A 755 Ω – 885 Ω • Do not press ohmmeter probes strongly against terminals of front airbag sensor. • Make sure the front airbag sensor connector is properly connected. NG Replace front airbag sensor. Repair or replace harness or connector between center airbag sensor assembly and front airbag sensor (See page RS–27). Check spiral cable. Disconnect connector between center airbag sen– sor assembly and spiral cable. Measure resistance between D+, D– on spiral ca– ble side of connector between spiral cable and steering wheel pad and body ground. Resistance: 1 M Ω or higher Repair or replace spiral cable. Repair or replace harness or connector between center airbag sensor assembly and spiral cable. RS–88 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DTC 12 Short in Squib Circuit (to B+) CIRCUIT DESCRIPTION The squib circuit consists of the center airbag sensor assembly, spiral cable and the steering wheel pad (squib). It causes the airbag to deploy when the airbag deployment conditions are satisfied. The front airbag sensor detects the deceleration force in a frontal collision and is located in the front fender on the left and right sides. For details of the function of each component, see FUNCTION OF COMPONENTS on page RS–10– Diagnostic trouble code 12 is recorded when a +B short is detected in the squib circuit or the front airbag sensor circuit. Diagnosis DTC No. • • • • • • Short circuit in squib wire harness (to +B). Squib malfunction. Short circuit in front airbag sensor +S wire harness (to +B). Open circuit in RH and LH front airbag sensor harness. Spiral cable malfunction. Center airbag sensor assembly malfunction. WIRING DIAGRAM RS–89 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSTIC CHART Preparation. Check front airbag sensor circuit. (Measure resistance between terminals +SR and – SR, +SL and –SL of center airbag sensor assembly connector.) Check front airbag sensor circuit. (Measure voltage between terminal +SR or +SL of center airbag sensor assembly connector and body ground.) Check front airbag sensor circuit. (Measure voltage between terminals D+ and D– of center airbag sensor assembly connector and body ground.) Check front airbag sensor circuit. (Measure voltage between terminals P+ and P’ of center airbag sensor assembly connector and body ground.) Check center airbag sensor assembly. Check D squib. Check P squib. Go to Code 15 (See page RS–110). Repair or replace harness or connector between center airbag sensor assembly and front airbag sensor (See page RS–50). Go to step [9] Repair or replace harness or connector between front airbag sensor and center airbag sensor assembly. (See page RS–50). Replace center airbag sensor assembly. Replace steering wheel pad. Replace front passenger airbag assem– bly. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Check spiral cable. Repair or replace harness or connecter between center airbag sensor assembly and spiral cable. Repair or replace spiral cable. RS–90 SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURES – TROUBLESHOOTING Preparation Check Preparation. (1) Disconnect battery negative H terminal cable, and wait at least 90 seconds. (2) Remove steering wheel pad (See page RS– 20). (3) Disconnect connectors of front passenger airbag assembly. (See page RS–29) Store the steering wheel pad with the front surface facing upward. Check front airbag sensor circuit. (Measure resistance between terminals +SR and –SR, +SL and –SL of center airbag sensor assembly connector.) Disconnect center airbag sensor assembly con– nector. Measure resistance between terminals +SR and –SR, +SL and –SL of harness side connector of center airbag sensor assembly. Resistance: 755
– 885
Go to Code 15 (See page RS–110). RS–91 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check front airbag sensor circuit. (Measure voltage between terminal +SR or +SL of center airbag sensor assembly connector and body ground.) (1) Connect negative (–) terminal cable to battery. (2) Turn ignition switch ON. Measure voltage between terminals +SR or +SL of harness side connector of center airbag sensor assembly and body ground. Voltage: Below 1 V Repair or replace harness or connector between center airbag sensor assembly and front airbag sensor (See page RS–50). Check D squib circuit. Measure voltage at D+ on spiral cable side of connector between spiral cable and steering wheelpad. Voltage: Below 1 V G o to step RS–92 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check P squib circuit. Measure voltage at P+ on center airbag sensor assembly side of connector between center airbag sensor assembly and front passenger airbag assembly. Voltage: Below 1 V Repair or replace harness or connector between front airbag sensor and center airbag sensor assembly. (See page RS–50). Check D squib circuit. (1) Turn ignition switch LOCK. (2) Disconnect negative H terminal cable from battery. (3) Connect connector to center airbag sensor assembly. (4) Using a service wire, connect D+ and D– on spiral cable side of connector between spiral cable and steering wheel pad. (5) Using a service wire, connect P+ and P– on wire harness connector and front passenger airbag assembly. (6) Connect negative H terminal cable to battery, and wait at least 2 seconds. (7) Turn ignition switch ACC on ON and wait at least 20 seconds. Clear malfunction code. Turn ignition switch LOCK, and wait at least 20 seconds. (1) Turn ignition switch ACC or ON, and wait at least 20 seconds. (2) Using SST, connect terminals Tc and El of DLC1 or DLC2. SST 09843–18020 (3) Check diagnostic trouble code. Diagnostic trouble code 12 is not output. Codes other than code 12 may be output at this time, but they are not relevant to this check. Replace center airbag sensor assembly. RS–93 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check D squib. (1) Turn ignition switch LOCK. (2) Disconnect battery negative 1–) terminal cable, and wait at least 90 seconds. (3) Connect steering wheel pad (squib) connector. (4) Connect negative H terminal cable to battery, and bait at least 2 seconds. (5) Turn ignition switch, ACC or ON, and wait at least 20 seconds. Clear malfunction code. Turn ignition switch LOCK, and wait at least 20 seconds. (1) Turn ignition switch ACC or ON, and wait at least 20 seconds (2) Using SST, connect terminals Tc and El of DLC1 or DLC2. SST 09843–18020 (3) Check diagnostic trouble code. Diagnostic trouble code 12 is not output. Code other than code 12 may be output at this time, but they are not relevant to this check. Replace steering wheel pad. Check P squib. (1) Turn ignition switch LOCK. (2) Disconnect battery negative (–) terminal cable, and wait at least 90 seconds. (3) Connect front passenger airbag assembly (squib) connector. (4) Disconnect steering wheel pad (squib)connector. (5) Connect negative (–) terminal cable to battery, and wait at least 2 seconds. (6) Turn ignition switch ACC or ON and wait at least 20 seconds. Clear malfunction code. Turn ignition switch LOCK, and wait at least 20 seconds. (1) Turn ignition switch ACC or ON, and wait at least 20 seconds. (2) Using SST, connect terminals Tc and El of DLC1 or DLC2. (3) Check diagnostic trouble code. Diagnostic trouble code 12 is not output. Codes other than code 12 may be output at this time, but they are not relevant to this check. Replace center airbag sensor assembly. RS–94 SUPPLEMENTAL RESTRAINT SYSTEM – SUPPTROUBLESHOOTING From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Check spiral cable. (1) Turn ignition switch LOCK. (2) Disconnect connector between center airbag sensor assembly and spiral cable (3) Turn ignition switch ON. Measure voltage at D+ on spiral cable side of con– nector between spiral cable and steering wheel pad. Voltage: Below 1 V Repair or replace spiral cable. Repair or replace harness or connector between center airbag sensor assembly and spiral cable. RS–95 SUPPLEMENTAL RESTRAINT SYSTEM – MEMO – – TROUBLESHOOTING RS–96 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DTC 13 Short in Squib Circuit (Between D+ Wire Harness and D– Wire Harness) CIRCUIT DESCRIPTION The squib circuit consists of the center airbag sensor assembly, spiral cable and the steering wheel pad (squib). It causes the airbag to deploy when the airbag deployment conditions are satisfied. For details of the function of each component, see FUNCTION OF COMPONENTS on page RS–10– Diagnostic trouble code 13 is recorded when a short is detected in the D+ wire harness and D– wire harness of the squib circuit. Diagnosis DTC No. • • • • Short circuit between D+ wire harness and D– wire harness of squib. Squib malfunction. Spiral cable malfunction. Center airbag sensor assembly malfunction. DIAGNOSTIC CHART Preparation. Check D squib circuit. Go to step Check center airbag sensor assembly. Replace center airbag sensor as– sembly. Check D squib. Replace steering wheel pad. From the results of the above inspection, the malfunctioning part can now be con– sidered normal. To make sure of this, use the simulation method to check. on next page. RS–97 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSTIC CHART (Cont’d) Check spiral cable. Repair or replace spiral cable. Check harness between center airbag sen– sor assembly and spiral cable. Repair or replace harness or con– nector between center airbag sen– sor assembly and spiral cable. Check center airbag sensor assembly. Replace center airbag sensor as– sembly. From the results of the above inspection, the malfunctioning part can now be con– sidered normal. To make sure of this, use the simulation method to check. WIRING DIAGRAM RS–98 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Preparation INSPECTION PROCEDURE Check Preparation. (1) Disconnect battery negative (–) terminal cable, and wait at least 90 seconds. (2) Remove steering wheel pad (See page RS– 20). (3) Disconnect connectors of front passenger airbag assembly and seat belt pretensioners. (See page RS–29) Store the steering wheel pad with the front surface facing upward. Check D squib circuit. Measure resistance between D+ and D– on spiral cable side of connector betwen spiral cable and steering wheel pad. Resistance: 1 k
or higher Go to step RS–99 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check center airbag sensor assembly. (1) Connect negative (–) terminal cable to battery. (2) Clear malfunction. (3) Turn ignition switch LOCK, and wait at least 20 seconds. (1) Turn ignition switch ACC or ON, and wait at least 20 seconds. (2) Using SST, connect terminals Tc and El of DLC1 or DLC2. SST 09843–18020 (3) Check diagnostic trouble code. Diagnostic trouble code 13 is not output. Codes other than code 13 may be output at this time, but they are not relevant to this check. Replace center airbag sensor assembly. Check D squib. (1) Turn ignition switch LOCK. (2) Disconnect battery negative (–) terminal cable, and wait at least 90 seconds. (3) Connect steering wheel pad (squib) connector. (4) Connect negative (–) terminal cable to battery. (5) Clear malfunction. (6) Turn ignition switch LOCK, and wait at least 20 seconds. (1) Turn ignition switch ACC or ON and wait at least 20 seconds. (2) Using SST, connect terminals Tc and El of DLC1 or DLC2. SST 09843–18020 (3) Check diagnostic trouble code. Diagnostic trouble code 13 is not output. Codes other than code 13 may be output at this time, but they are not relevant to this check. Replace steering wheel pad. RS–100 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Check spiral cable. (1) Disconnect connector between center airbag sensor assembly and spiral cable. (2) Release airbag activation prevention mecha– nism on center airbag sensor assembly side of spiral cable connector (See page RS–102). Measure resistance between D+ and D– on spiral cable side of connector between spiral cable and steering wheel pad. Resistance: 1 M
or higher Repair or replace spiral cable. Check harness between center airbag sensor assembly and spiral cable. (1) Disconnect center airbag sensor assembly connector. (2) Release airbag activation prevention mecha– nism on center airbag sensor assembly con– nector (See page RS–50). Measure resistance between D+ and D– on center airbag sensor assembly side of connector between center airbag sensor assembly and spiral cable. Resistance: 1 M
or higher Repair or replace harness or connector between center airbag sensor assembly and spiral cable. RS–101 SUPPLEMENTAL RESTRAINT SYSTEM – SUPPLEMENTAL RESTRAINT SYSTEM TROUBLESHOOTING 7. Check center airbag sensor assembly. P Front Passenger Airbag Assembly Center Airbag Sensor Assembly Spiral Cable 0 Steering Wheel Pad (Squib) Connect center airbag sensor assembly connector. Measure resistance between D+ and D– on center airbag sensor assembly side of connector between center airbag sensor assembly and spiral cable. Resistance: 1 KM Ω or higher 805905 AB0068 Replace center airbag sensor assembly. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. RS–102 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING RELEASE METHOD OF AIRBAG ACTIVATION PREVENTION MECHANISM An airbag activation prevention mechanism is built into the connector for the squib circuit of the supplemental restraint system. When release of the airbag activation prevention mechanism is directed in the troubleshooting procedure, as shown in the illustration of the connector T and 0 below, insert paper which is the same thickness as the male terminal, between the terminal and the short spring CAUTION: • NEVER RELEASE the airbag activation prevention mechanism on the steering wheel pad connector. NOTICE: • Do not release the airbag activation prevention mechanism unless specifically directed by the troubleshooting procedure. • If the paper inserted is too thick the terminal and short spring may be damaged, so always use paper the same thickness as the male terminal. RS–103 SUPPLEMENTAL RESTRAINT SYSTEM – MEMO – – TROUBLESHOOTING RS–104 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DTC 14 Open in D Squib Circuit CIRCUIT DESCRIPTION The squib circuit consists of the center airbag sensor assembly, spiral cable and the steering wheel pad (squib). It causes the airbag to deploy when the airbag deployment conditions are satisfied. For details of the function of each component, see FUNCTION OF COMPONENTS on page RS–10. Diagnostic trouble code 14 is recorded when an open is detected in the squib circuit. Diagnosis DTC No. • • • • Open circuit in D+ wire harness or D‘ wire harness of squib. Squib malfunction. Spiral cable malfunction. Center airbag sensor assembly malfunction. RS–105 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSTIC CHART Preparation. Check D squib circuit. Go to step Check spiral cable. Repair or replace spiral cable. Check harness between center airbag sen– sor assembly and spiral cable. Repair or replace harness or con– nector between center airbag sen– sor assembly and spiral cable. Check center airbag sensor assembly. Replace center airbag sensor as– sembly. Check D squib. Replace steering wheel pad. From the results of the above inspection, the malfunctioning part can now be con– sidered normal. To make sure of this, use the simulation method to check. WIRING DIAGRAM RS–106 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING INSPECTION PROCEDURE Preparation Check Preparation. (1) Disconnect battery negative (–) terminal cable, and wait at least 90 seconds. (2) Remove steering wheel pad (See page RS–20). (3) Disconnect connectors of front passenger airbag assembly. (See page RS–29) Store the steering wheel pad with the front surface facing upward. Check D squib circuit. Disconnect center airbag sensor assembly con– nectors. Measure resistance between D+ and D– on spiral cable side of connector between spiral cable and steering wheel pad. Resistance: Below 1
Go to step RS–107 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check spiral cable. Disconnect connector between center airbag sen– sor assembly and spiral cable. Measure resistance between D+ and D– on spiral cable side of connector between spiral cable and steering wheel pad. Resistance: Below 1 Ω Repair or replace spiral cable. Check harness between center airbag sensor assembly and spiral cable. Measure resistance between D+ and D– on center airbag sensor assembly side of connector between center airbag sensor assembly and spiral cable. Resistance: Below 1 Ω Repair or replace harness or connector between center airbag sensor assembly and spiral cable. RS–108 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check center airbag sensor assembly. (1) Connect connector to center airbag sensor connector. (2) Connect connector between center airbag sensor assembly and spiral cable. (3) Using a service wire, connect D+ and D– on spiral cable side of connector between spiral cable and steering wheel pad. (4) Connect negative (–) terminal cable to battery, and wait at least 2 seconds. (5) Turn ignition switch ACC on ON and wait at least 20 seconds. Clear malfunction code. Turn ignition switch LOCK, and wait at least 20 seconds. (1) Turn ignition switch ACC or ON, and wait at least 20 seconds. (2) Using SST, connect terminals Tc and El of DLC1 or DLC2. SST 09843–18020 (3) Check diagnostic trouble code. Diagnostic trouble code 14 is not output. Codes other than code 14 may be output at this time, but they are not relevant to this check. Replace center airbag sensor assembly. Check D squib. (1) Turn ignition switch LOCK. (2) Disconnect battery negative H terminal cable, and wait at least 90 seconds. (3) Connect steering wheel pad (squib) con– nector. (4) Connect negative (–y terminal cable to bat– tery, and wait at least 2 seconds. (5) Turn ignition switch ACC or ON, and wait at least 20 seconds. (6) Clear malfunction code. Turn ignition switch LOCK, and wait at least 20 seconds. Turn ignition switch ACC or ON, and wait at least 20 seconds (2) Using SST, connect terminals Tc and El of DLC1 or DLC2. SST 09843–18020 (3) Check diagnostic trouble code. Diagnostic trouble code 14 is not output. Code other than code 14 may be output at this time, but they are not relevant to this check. Replace steering wheel pad. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. RS–109 SUPPLEMENTAL RESTRAINT SYSTEM – MEMO – – TROUBLESHOOTING RS–110 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DTC 15 Open in Front Airbag Sensor Circuit CIRCUIT DESCRIPTION The front airbag sensor detects the deceleration force in a frontal collision and is located in the front fender on the left and right sides. For details of the function of each component, see FUNCTION OF COMPONENTS on page RS–10. Diagnostic trouble code 15 is recorded when an open is detected in the front airbag sensor circuit. NOTICE: The front airbag sensor connector is equipped with an electrical connection check mech– anism for the purpose of detecting an open in the front airbag sensor (See page RS–13). This mech– anism is constructed so that when the terminals of the front airbag sensor have been connected (when the connector housing lock is in the locked condition), the connection detection pin on the wire harness side connects with the terminals for diagnosis use on the sensor side. If the connector is not properly connected, the diagnosis system, may detect only a malfunction code, even though the supplemental restraint system is functioning normally. When connecting the front airbag sensor connector, make sure it is connected properly. If diagnostic trouble code 15 is displayed after the front airbag sensor connector has been connected, check again that it is properly connected. Diagnosis DTC No. • • • • • Open circuit in +S wire harness or –S wire harness of front airbag sensor. Short circuit in front airbag sensor +S wire harness (to +B). Front airbag sensor malfunction. Malfunction of electrical connection check mechanism of front airbag sensor. Center airbag sensor assembly malfunction. WIRING DIAGRAM RS–111 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSTIC CHART Preparation. Check front airbag sensor circuit (Measure resistance between terminals +SR and –SR, +SL and –SL of center airbag sensor assembly connector). Go to step Check front airbag sensor circuit (Measure voltage between terminal +SR or +SL. and of center airbag assembly con– nector and body ground). Repair or replace harness or con– nector between center airbag sen– sor assembly and front airbag sensor. (See page RS–50). Check center airbag sensor assembly. Replace center airbag sensor as– sembly. From the results of the above inspection, the malfunctioning part can now be con– sidered normal. To make sure of this, use the simulation method to check. Check front airbag sensor. Replace front airbag sensor. Check harness between center airbag sen– sor assembly and front airbag sensor. Repair or replace harness or con– nector between center airbag sen– sor. assembly and front airbag sesor. (See page RS–50). Replace front airbag sensor connector (See page RS–50). RS–112 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING INSPECTION PROCEDURE Preparation Check Preparation. (1) Disconnect battery negative (–) terminal cable, and wait at least 90 seconds. (2) Remove steering wheel pad (See page RS– 20). (3) Disconnect connectors of front passenger airbag assembly. (See page RS–29) Store the steering wheel pad with the front surface facing upward. Check front airbag sensor circuit (Measure resistance between terminals +SR and –SR, +SL and –SL of center airbag sensor assembly connector.). Disconnect center airbag sensor assembly con– nectors. Measure resistance between terminals +SR and –SR, +SL and –SL of harness side connector of center airbag sensor assembly. Resistance: 755
– 885
Go to step RS–113 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check front airbag sensor circuit. (Measure voltage between terminal +SR or +SL of center airbag sensor assembly connector and body ground.) (1) Connect negative H terminal cable to battery. (2) Turn ignition SWitch ON. Measure voltage between terminals +SR or +SL ofharness side connector of center airbag sensor assembly and body ground. Voltage: Below 1 V Repair or replace harness or connector between center airbag sensor assembly and front airbag sensor (See page RS–50). Check center airbag sensor assembly. (1) Turn ignition switch LOCK. (2) Disconnect negative (–) terminal cable from battery. (3) Connect connector to center airbag sensor assembly. (4) Using a service wire, connect D+ and D– on spiral cable side of connector between spiral cable and steering wheel pad. (5) Using a service wire, connect P+ and P– on wire harness connector side of connector be– tween wire harness connector and front pas– senger airbag. . (6) Connect negative (–) terminal cable to battery, and wait at least 2 seconds. (7) Turn ignition switch ACC or ON and wait at least 20 seconds. Clear malfunction code. Turn ignition switch LOCK and wait at least 20 seconds. (1) Turn ignition switch ACC or ON and wait at least 20 seconds. (2) Using SST, connect terminals Tc and El of DLC1 or DLC2. SST 09843–18020 (3) Check diagnostic trouble code. Diagnostic trouble code 15 is not output. Codes other than code 15 may be output at this time, but they are not relevant to this check. Replace center airbag sensor assembly. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. RS–114 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check front airbag sensor. Disconnect front airbag sensor connector. Measure resistance between each terminal of front airbag sensor. Terminal Resistance • Do not press ohmmeter probes too strongly against terminals of front airbag sensor. • Make sure the front airbag sensor connector is properly connected. Replace front airbag sensor. Check harness between center airbag sensor assembly and front airbag sensor. (1) Disconnect center airbag sensor assembly connectors. (2) Using service wires, connect +SR and –SR, +SL and –SL on the wire harness side of the center airbag sensor assembly connectors. Measure resistance between terminals +SR and –SR, +SL and –SL of harness side connector of front airbag sensor. • Lightly touch ohmmeter probes at position shown in illustration. • Make sure the front airbag sensor connector is properly connected. Resistance: Below 1
Repair or replace harness or connector between center airbag sensor assembly and front airbag sensor (See page RS–50). Replace front airbag sensor connector (See page RS–50). RS–115 SUPPLEMENTAL RESTRAINT SYSTEM – MEMO – – TROUBLESHOOTING RS–116 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DTC 22 SRS Warning Light System Malfunction CIRCUIT DESCRIPTION The SRS warning light is located on the cluster finish panel. when the SRS is normal, the SRS warning light lights up for approx.6 seconds after the ignition switch is turned from LOCK position to ACC or ON position, and then turns off automatically. If there is a malfunction in the SRS, the SRS warning light lights up to inform the driver of the abnormality. When terminals Tc and E1of the DLC1 or DLC2 are connected, the diagnostic trouble code is displayed by the blinking of the SRS warning light. The SRS warning light circuit is equipped with an electrical connection check mechanism which detects when the connector to the center airbag sensor assembly is not properly connected. If the connector to the center airbag sensor assembly is not properly connected, the SRS warning light will not light up. Diagnostic trouble code 22 is recorded when a malfunction occurs in the SRS warning light system. If an OPEN malfunction occurs in the SRS warning light system, the SRS warning light does not light up, so that until the malfunction is repaired, the diagnostic trouble codes (including code 22f cannot be confirmed. DTC No. • • Diagnosis Open circuit in SRS warning light system. Center– airbag sensor assembly malfunction. RS–117 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSTIC CHART Troubleshooting for this system is different for when the SRS warning light does not light up and for when diagnostic trouble code 22 is output. Confirm the problem symptoms first before selecting the appropriate troubleshooting procedure. HINT: If SRS warning light does not light up, perform the following troubleshooting: Check ECU–B Fuse. G o to step Check connection of center airbag sensor assembly connector. Repair. Preparation. Check SRS warning light circuit. Does SRS warning light come on? YES Repair SRS warning light circuit. Check terminal LA of center airb– ag sensor assembly and electrical connection check mechanism. If normal, replace center airbag sensor assembly. From the results of the above inspection, the malfunctioning part can now be con– sidered normal. To make sure of this, use the simulation method to check. Is ECU–B Fuse burnt out again? YES Check harness between ECU–B fuse and SRS warning. light. Using simulation method, repro– duce malfunction symptoms (See page RS–67). RS–118 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSTIC CHART HINT: If diagnostic trouble code 22 is output, perform the following troubleshooting: NO Using simulation m Using simulation method, repro– Is diagnostic trouble code 22 output again? duce malfunction symptoms (See page RS–67). YES Replace center airbag sensor assembly. WIRING DIAGRAM RS–119 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Preparation INSPECTION PROCEDURES HINT: IF SRS warning light does not light up, perform the following troubleshooting: Check Check ECU–B fuse. Remove ECU–B fuse. Check continuity of ECU–13 fuse. Continuity • Fuse may be burnt out even if it appears to be OK during visual inspection. • If fuse is OK, instal it. Go to step Check connection of center airbag sensor assembly connector. Repair. Preparation. (1) Disconnect negative (–) terminal cable from the battery, and wait at least 90 seconds. (2) Remove steering wheel pad (See page RS– 20). (3) Disconnect connector of front passenger airbag assembly. (See page RS–29). Store the steering wheel pad with the front surface facing upward. RS–120 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check SRS warning light circuit. (1) Disconnect center airbag sensor assembly connector. (2) Connect negative (–) terminal cable to battery. (3) Turn ignition switch ACC or ON. Measure voltage LA terminal of harness side con– nector of center airbag sensor assembly. Voltage: Battery positive voltage Repair SRS warning light circuit. Does SRS warning light come on? (1) Disconnect negative H terminal cable from the battery. (2) Connect center airbag sensor assembly con– nector. (3) Connect negative 1–y terminal cable to battery, and wait at least 2 seconds. (4) Turn ignition switch ACC or ON. Check operation of SRS warning light. SRS warning light comes on. YES Check terminal LA of center airbag sensor assembly and electrical connection check mechanism. If normal, replace center airbag sensor assembly. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. Is new ECU–B fuse burnt out again? YES Using simulation method, reproduce malfunction symptoms (See page RS–67). Check harness between ECU–B fuse and SRS warning light. RS–121 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING HINT: If diagnostic trouble code 22 is output, perform the following troubleshooting: Is diagnostic trouble code 22 output again? (1) Turn ignition switch LOCK, and wait at least 2 seconds. (2) Turn ignition switch ACC or ON, and wait at least 20 seconds. (3) Clear malfunction code stored in memory. (See page RS–65) (4) Turn ignition switch LOCK, and wait at least 20 seconds. (5) Turn ignition switch ACC or ON, and wait at least 20 seconds. (6) Using SST, connect terminals Te and El of DLC1 or DLC2. SST 09843–18020 (7) Check diagnostic trouble code. YES Replace center airbag sensor assembly. Using simulation method, reproduce malfunction symptoms (See page RS–67). RS–122 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DTC 24 Open in Center Airbag Sensor Assembly Connectors Malfunction CIRCUIT DESCRIPTION The center airbag sensor assembly detects partial connection of connectors. For details of the function of each component, see FUNCTION OF COMPONENTS on page RS–10. When the center airbag sensor assembly detects an open in the electrical connection check mechanism of the center airbag sensor connector or in the center airbag sensor circuit, trouble code 24 is recorded. Diagnosis DTC No. • • Malfunction of electrical connection check mechanism of center airbag sensor assembly connectors. Center airbag sensor assembly malfunction. RS–123 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSTIC CHART Are connectors of center airbag sensor assembly properly connected? Check unfitting detector pin in the center airbag sensor assembly connector. Check center airbag sensor assembly. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simula– tion method to check. Connect connectors. Repair or replace center airbag sensor assembly connector. Replace center airbag sensor asse– mbly. RS–124 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING INSPECTION PROCEDURE Preparation Check Are connector of center airbag sensor assembly properly connected? Connect connectors. Check unfitting detector pin in the center airbag sensor assembly connector. (1) Disconnect negative (–) terminal cable from battery. (2) Disconnect center airbag sensor assembly. Test for continuity. Continuity exists. Repair or replace center airbag sensor assembly connector. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. RS–125 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check center– airbag sensor assembly. (1) Disconnect negative (–y terminal cable from battery. (2) Connect center airbag sensor assembly. (3) Connect negative H terminal cable to battery. (4) Turn ignition switch ACC or ON. Check diagnostic trouble code. Diagnostic trouble code 24 is not output. Replace center airbag sensor assembly. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. RS–126 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DTC 31 Center Airbag Sensor Assembly Malfunction CIRCUIT DESCRIPTION The center airbag sensor assembly consists of a center airbag sensor, safing sensor, ignition control and drive circuit, diagnosis circuit, etc. It receives signals from the airbag sensors, judges whether or not the airbag must be deploy, and diagnosis system malfunction. Diagnostic trouble code 31 is recorded with occurrence of a malfunction in the center airbag sensor assembly is detected. Diagnosis DTC No. • Center airbag sensor assembly malfunction. DIAGNOSTIC CHART HINT: When a malfunction code other than code 31 is displayed at the same time, first repair the malfunction indicated by the malfunction code other than code 31. Is diagnostic trouble code 31 output again? YES Replace center airbag sensor assembly. NO Using simulation method, repro– duce malfunction symptoms (See INTRODUCTION). RS–127 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING INSPECTION PROCEDURE HINT: When a malfunction code other than code 31 is displayed at the same time, first repair the malfunc– tion indicated by the malfunction code other than code 31. Preparation Check Is diagnostic trouble code 31 output again? Clear malfunction code. (1) Turn ignition switch LOCK, and wait at least 20 seconds. (2) Turn ignition switch ACC or ON, and wait at least 20 seconds. (3) Repeat operation in step (1) and (2) at least 5 times. (4) Using SST, connect terminals Tc and El of DLC1 or DLC2. SST 09843–18020 (5) Check diagnostic trouble code. YES Replace center airbag sensor assembly. Using simulation method, reproduce malfunction symptoms (See INTRODUCTION). RS–128 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DTC 53 Short in P Squib Circuit (Between P+ Wire Harness and P– Wire Harness) CIRCUIT DESCRIPTION The squib circuit consists of the center airbag sensor assembly, (squib). It causes the airbag to deploy when the airbag deployment conditions are satisfied. For details of the function of each component, see FUNCTION OF COMPONENTS. on page RS–10– Diagnostic trouble code 53 is recorded when a short is detected in the P+ wire harness and P– wire harness of the squib circuit. Diagnosis DTC No. • • • Short circuit between P+ wire harness and P– wire harness of squib. Squib malfunction. Center airbag sensor assembly malfunction. DIAGNOSTIC CHART Preparation. on next page. Check P squib circuit. G o to step Check center airbag sensor assembly. Replace center airbag sensor as– sembly. Check P squib. Replace front passenger airbag assembly. From the results of the above inspection, the malfunctioning part can now be con– sidered normal. To make sure of this, use the simulation method to check. RS–129 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSTIC CHART (Cont’d) Check P circuit. Check center airbag sensor assembly. From the results of the above inspection, the malfunctioning part can now be con– sidered normal. To make sure of this, use the simulation method to check. WIRING DIAGRAM Repair or replace harness or con– nector between center airbag sen– sor assembly and front passenger airbag assembly. Replace center airbag sensor as– sembly. RS–130 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING INSPECTION PROCEDURE Preparation Check Preparation. (1) Disconnect battery negative H terminal cable, and wait at least 90 seconds. t2y Remove steering wheel pad (See page RS– 20). (3) Disconnect connectors of front passenger airbag assembly (See page RS–29). Store the steering wheel pad with the front surface facing upward. Check Psquib circuit. For the connector (on the center airbag sensor assembly side) between the center airbag sensor assembly and front passenger airbag assembly, measure the resistance between P+ and P’. Resistance: 1 k
or higher Go to step RS–131 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check center airbag sensor assembly. (1) Connect negative (–) terminal cable to battery, and wait at least 2 seconds. (2) Clear malfunction code stored in memory (See page RS–65). (3) Turn ignition switch LOCK, and wait at least 20 seconds. (1) Turn ignition switch ACC or ON and wait at least 20 seconds. (2) Using SST, connect terminals Tc and El of D LC 1 or D LC2 . SST 09843–18020 (3) Check diagnostic trouble code. Diagnostic trouble code 53 is not output. Codes other than code 53 may be output at this time, but they are not relevant to this check. Replace center airbag sensor assembly. RS–132 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check P squib. (1)Turn ignition switch–LOCK. (2) Disconnect battery negative (–) terminal cable and wait at least 90 seconds. (3) Connect front passenger airbag assembly connector. (4) Connect negative H terminal cable to battery, and wait at least 2 seconds. (5)Clear malfunction code (See page RS–65). (6) Turn ignition switch ACCor ON, and wait at least 20 seconds. (1)Turn ignition switch ACC or ON and wait at least 20 seconds (2)Using SSt, connect terminals Tc and E1 of DLC1 or DLC2. SST 09843–18020 (3) Check diagnostic trouble code. Diagnostic trouble code 53 is not output. Codes other than code 54 may be output at this time, but they are not relevant to this check. Replace front passenger airbag assembly. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. RS–133 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check P circuit (1) Disconnect center airbag sensor assembly connector. (2) Release airbag activation prevention mecha– nism on center airbag sensor assembly con– nector (See page RS–102). For the connector (on the center airbag sensor as– sembly side) between the center airbag sensor assembly and front passenger airbag assembly, measure the resistance between P+ and P–. Resistance: 1 k
or higher Repair or replace harness or connector between center airbag sensor assembly and front passenger airbag assembly. Check center airbag sensor assembly. Connect center airbag sensor assembly connec– tor. For the connector (on the center airbag sensor assembly side) between the center airbag sensor assembly and front passenger airbag assembly, measure the resistance between P+ and P–. Resistance: 1 k
or higher Replace center airbag sensor assembly. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. RS–134 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DTC 54 Open in P Squib Circuit CIRCUIT DESCRIPTION The squib circuit consists of the center airbag sensor assembly, wiring harness connector and front passenger airbag assembly. It causes the airbag to deploy when the airbag deployment conditions are satisfied. For details of the function of each component, see FUNCTION OF COMPONENTS on page RS–10. Diagnostic trouble code 54 is recorded when an open is detected in the squib circuit. Diagnosis DTC No. • • • Open circuit in P+ wire harness and P– wire harness of squib. Squib malfunction. Center airbag sensor assembly malfunction. RS–135 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSTIC CHART Preparation. Check P squib circuit. Check center airbag sensor assembly. Check P squib. From the results of the above inspection, the malfunctioning part can now be con– sidered normal. To make sure of this, use the simulation method to check. WIRING DIAGRAM Repair or replace harness or con– nector between center airbag sen– sor assembly and front airbag sensor (See page RS–13). Replace center airbag sensor as– sembly. Replace front passenger airbag assembly. RS–136 SUPPLEMENTAL RESTRAINT SYSTEM INSPECTION PROCEDURE – TROUBLESHOOTING Preparation Check Preparation. (1) Disconnect battery negative (–) terminal cable, and wait at least 90 seconds. (2) Remove steering wheel pad (See page RS–20). (3) Disconnect connectors of front passenger airbag assembly (See page RS–29). Store the steering wheel pad with the front surface facing upward. Check P squib circuit. Disconnect center airbag sensor assembly con– nector. For the connector (on the center airbag sensor assembly side) between the center airbag sensor assembly and front passenger airbag assembly, measure the resistance between P+ and P–. Resistance: Below 1
Repair or replace harness or connector between center airbag sensor assembly and front passenger airbag assembly. RS–137 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check center airbag sensor assembly. (1) Connect connectors to center airbag sensor assembly. (2) Using a service wire, connect D+ and D– on spiral cable side of connector between spiral cable and steering wheel pad. (3) Using a service wire, connect P+ and P’ on center airbag sensor assembly side of connec– tor between center airbag sensor assembly and front passenger airbag assembly. (4) Connect negative (–) terminal cable to battery, and wait at least 2 seconds. (5)Turn ignition switch ACC or ON ON (6)Clear malfunction code stored in memory (see page RS–65) (7)Turn ignition switch LOCK, and wait at least 20 seconds. (1)Turn ignition switch ACC or ON and wait at least 20 seconds (2)Using SSt, connect terminals Tc and E1 of DLC1 or DLC2. SST 09843–18020 (3) Check diagnostic trouble code. Diagnostic trouble code 54 is not output. Codes other than code 54 may be output at this time, but they are not relevant to this check. Replace center airbag sensor assembly. RS–138 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check P squib. Turn ignition switch LOCK. (2) Disconnect battery negative 1–y terminal cable and wait at least 90 seconds. (3) Connect front passenger airbag assembly connector. (4) Connect negative 1–y terminal cable to battery, and wait at least 2 seconds. (5) Turn ignition switch ACC or ON and wait at least 20 seconds. (6) Clear malfunction code stored in memory (See page RS–65). (7) Turn ignition switch LOCK, and wait at least 20 seconds. (1) Turn ignition switch ACC or ON, and wait at least 20 seconds. (2) Using SST, connect terminals Tc and E, of DLC1. SST 09843–18020 (3) Check diagnostic trouble code. Diagnostic trouble code 54 is not output. Codes other than code 54 may be output at this time, but they are not relevant to this check. Replace front passenger airbag assembly. From the results of the above inspection, the malfunctioning part can now be considered normal. To make sure of this, use the simulation method to check. RS–139 SUPPLEMENTAL RESTRAINT SYSTEM – MEMO – – TROUBLESHOOTING RS–140 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING SRS Warning Light System Malfunction CIRCUIT DESCRIPTION The SRS warning light is located on the combination meter. When the supplemental restraint system is normal, the SRS warning light lights up for approx. 6 seconds after the ignition switch is turned from LOCK position to ACC or ON position, and then turns off automatically. If there is a malfunction in the supplemental restraint system, the SRS warning light lights up to inform the driver of the abnormality. When terminals Tc and El of the check connector are connected, the diagnostic trouble code is displayed by the blinking of the SRS warning light. RS–141 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING DIAGNOSTIC CHART Troubleshooting for this system is different for when the SRS warning light does not light up. Confirm the problem symptoms first before selecting the appropriate troubleshooting procedure. HINT: If SRS warning light does not light up, perform the following troubleshooting: Check SRS fuse. NG Go to step Preparation. Check SRS warning light circuit. Repair SRS warning light circuit (See page BE–61). Does SRS warning light come on? Check terminal LA of center airbag sensor assembly and electrical connection check mechanism. If normal, replace center airbag sensor assembly. YES From the results of the above inspection, the malfunctioning part can now be con– sidered normal. To make sure of this, use the simulation method to check. Is new SRS fuse burnt out again? YES Check harness between SRS fuse and SRS warning light, and SRS fuse and center airbag sensor assembly. Using simulation method, repro– duce malfunction symptomes (See INTRODUCTION). RS–142 SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTIC CHART WIRING DIAGRAM – TROUBLESHOOTING RS–143 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Preparation INSPECTION PROCEDURE HINT: If SRS warning light does not light up, perform the following troubleshooting: Check Check SRS fuse. Go to step Preparation. Disconnect battery negative H terminal cable, and wait at least 90 seconds. (2) Remove steering wheel pad (See page RS–20). (3) Disconnect connectors of front passenger airbag assembly. (See page RS–29). Store the steering wheel pad with the front surface facing upward. RS–144 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check SRS warning light circuit. (1) Disconnect center airbag sensor assembly. (2) Connect negative (–) terminal cable to battery. (3) Turn ignition switch ACC or ON. Measure voltage LA terminal of harness side con– nector of center airbag sensor assembly. Battery Voltage: 10 – 14 V Repair SRS warning light circuit (See page BE–61). Does SRS warning light come on? (1) Disconnect negative (–) terminal cable from battery. (2) Connect center airbag sensor assembly. (3) Connect negative (–) terminal cable to battery. (4) Turn ignition switch ACC or ON. (1) Turn ignition switch OFF, and wait at least 6 seconds. (2) Turn ignition switch ON. YES Check terminal LA of center airbag sensor assembly and electrical connection check mechanism. If normal, replace center airbag sensor assembly. Is now SRS fuse burnt out again? YES Using simulation method, reproduce malfunction symptoms (See INTRODUCTION). Check harness between SRS fuse and SRS warning light, and SRS fuse and center airbag sensor assembly. RS–145 SUPPLEMENTAL RESTRAINT SYSTEM – MEMO – – TROUBLESHOOTING RS–146 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING SRS Warning Light System (Always Lit Up when ignition switch is LOCK position) CIRCUIT DESCRIPTION The SRS warning light is located on the combination meter. When the supplemental restraint system is normal, the SRS warning light lights up for approx. 6 seconds after the ignition switch is turned from LOCK position to ACC or ON position, and then turns off automatically. If there is a malfunction in the supplemental restraint system, the SRS warning light lights up to inform the driver of the abnormality. When terminals Tc and El of the DLC1 or DLC2 are connected, the diagnostic trouble code is displayed by the blinking of the SRS warning light. DIAGNOSTIC CHART HINT: If the SRS warning light is always lit up by a DTC check procedure, perform Tc terminal circuit check procedure (See page RS–148). Does SRS warning light turn off? YES Replace center airbag sensor assembly. WIRING DIAGRAM Check SRS warning light circuit or terminal AB circuit of DLC1 or DLC2. RS–147 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING INSPECTION PROCEDURE Preparation Check Does SRS warning light turn off? Turn ignition switch LOCK. (2) Disconnect negative H terminal cable from battery and wait at least 90 seconds. (3) Remove steering wheel pad (See page RS– 20). (4) Disconnect connectors of front passenger airbag assembly. (See page RS–29) (5) Disconnect center airbag sensor assembly connector. (6) Connect negative H terminal cable to battery. Check operation of SRS warning light. Ignition Switch is LOCK position. YES Replace center airbag sensor assembly. Check SRS warning light circuit or terminal AB circuit DLC1 or DLC2. RS–148 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Tc Terminal Circuit CIRCUIT DESCRIPTION By connecting terminals Tc and El of the DLC1 or DLC2, the center airbag sensor assembly is set in the diagnostic trouble code output mode. The diagnostic trouble codes are displayed by the blinking of theSRS warning light. DIAGNOSTIC CHART Troubleshooting for this system is different depending on whether the diagnostic trouble code is not displayed SRS warning light is always lit up with a DTC check procedure, or is displayed without a DTC check procedure. Confirm the problem symptoms first before selecting the appropriate troubleshooting procedure. HINT: If the diagnostic trouble code is not displayed or SRS warning light is always lit up with a DTC check procedure perform the following troubleshooting: Check voltage between terminals Tc and E, of DLC1 or DLC2. OK G o to step Check voltage between terminal Tc of DLC1 or DLC2 and body ground. Check harness between terminal E1 of DLC1 or DLC2 and body ground. Check center airbag sensor assembly. Check harness between center airbag sensor assembly and DLC1 or DLC2. Replace center airbag sensor assembly. HINT: If the diagnostic trouble code is continuously displayed without a DTC check procedure, per– form the following troubleshooting: Check resistance between terminal Tc of center airbag sensor assembly and body ground. Repair or replace harness or connector. Replace center airbag sensor as– sembly. RS–149 SUPPLEMENTAL RESTRAINT SYSTEM DIAGNOSTIC CHART WIRING DIAGRAM – TROUBLESHOOTING RS–150 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING INSPECTION PROCEDURE Preparation Check HINT: If the diagnostic trouble code is not displayed, perform the following troubleshooting: Check voltage between terminals Te and El of DLC1 or DLC2. Turn ignition switch ACC or ON. Measure voltage between terminals Tc and El of DLC1 or DLC2. Battery Voltage: 10 – 14 V Go to step 3 Check voltage between terminal Te of DLC1 or DLC2 and body ground. Measure voltage between terminal Tc of DLC1 or DLC2 and body ground. Battery Voltage: 10 – 14 V Check harness between terminal El of DLC1 or DLC2 and body ground. RS–151 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING Check center airbag sensor assembly. (1) Turn ignition switch LOCK. (2) Disconnect battery negative (–) terminal cable, and wait at least 90 seconds. (3) Remove steering wheel pad (See page RS– 20). (4) Disconnect connectors of front passenger airbag assembly. (See page RS–29). Check operation of SRS warning light. SRS warning light comes on. Check harness between center airbag sensor assembly and DLC1 or DLC2. Replace center airbag sensor assembly. RS–152 SUPPLEMENTAL RESTRAINT SYSTEM – TROUBLESHOOTING HINT: If the diagnostic trouble code is continuously displayed, perform the following troubleshooting. Check resistance between terminal Tc of center airbag sensor assembly and body ground. Turn ignition switch LOCK. (2) Disconnect center airbag sensor assembly connector. (3) Disconnect battery negative (–) terminal cable, and wait at least 90 seconds. (4) Remove steering wheel pad (See page RS– 20). (5) Disconnect connectors of front passenger airbag assembly. (See page RS–29). Check resistance between terminal Tc of center airbag sensor assembly and body ground. Resistance: 1 M
or higher Replace center airbag sensor assembly. Repair or replace harness or connector. RS–153 SUPPLEMENTAL RESTRAINT SYSTEM SERVICE SPECIFICATIONS SERVICE DATA TORQUE SPECIFICATIONS Part tightened Steering Wheel Steering wheel pad Front passenger airbag assembly Seat belt shoulder anchor bolt Front seat outer belt Front airbag sensor Center airbag sensor to instrument panel reinforcement to instrument panel – SERVICE SPECIFICATIONS SA–1 SUSPENSION AND AXLE – SUSPENSION AND AXLE SA–2 SUSPENSION AND AXLE – TROUBLESHOOTING TROUBLESHOOTING Wander/pulls Bottoming Sways/pitches Front wheel shimmy Abnormal tire wear SA–63 SA–10 Ball joint Hub bearings SA–3 SA–52 Shock absorber Wheel balance SA–66 Stabilizer bar Overloaded SA–52 Springs Suspension parts SA–4 SA–6 Wheel alignment Trouble Steering gear SA–96 Cold tire inflation pressure Parts Name Steering linkage SA–3 See Page Tires Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. SA–3 SUSPENSION AND AXLE – GENERAL INSPECTION GENERAL INSPECTION 1. INSPECT TIRE (a) Check the tires for wear and for the proper inflation pressure. Cold inflation pressure: See page SA–96 (b) Check the tire runout. Tire runout: 1.0 mm (0.039 in.) or less 2. INSPECT WHEEL BALANCE (a) Check and adjust the Off–the–car balance. (b) If necessary, check and adjust the On–the–car bal– ance. Unbalance after adjustment: 8.0 g (0.018 Ib) or less 3. CHECK WHEEL BEARING LOOSENESS (a) Check the backlash in bearing shaft direction. Maximum: 0.05 mm (0.0020 in.) (b) Check the axle hub deviation. Maximum: 0.05 mm (0.0020 in.) 4. 5. 6. 7. CHECK FRONT SUSPENSION FOR LOOSENESS CHECK STEERING LINKAGE FOR LOOSENESS CHECK BALL JOINT FOR EXCESSIVE LOOSENESS CHECK SHOCK ABSORBERS WORK PROPERLY • Check for oil leaks • Check mounting bushings for looseness • Bounce the vehicle up and down several times to stabilize the suspension. SA–4 SUSPENSION AND AXLE – WHEEL ALIGNMENT WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT 1. MEASURE VEHICLE HEIGHT Front vehicle height: SEDAN/COUPE: Tire size P195/70R14 Front 210 mm (8.27 in.) P205/65 R15 213 mm (8.39 in.) WAGON: Tire size P 195/70R 14 Front 210 mm (8.27 in.) P205/65R15 214 mm (8.43 in.) Measuring point: Measure from the ground to the center of the front side lower arm mounting bolt. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to specification. If the vehicle height is not standard, try to adjust it by pushing down on or lifting the body. 2. INSTALL CAMBER – CASTER – KINGPIN GAUGE ONTO VEHICLE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER, CASTER AND STEERING AXIS INCLINATION SEDAN/COUPE Cambar (Left –right error) –035’ ± 45’ (45’ or less) WAGON –0 35’±45’ (45’ or less) Caster (Left–right error) 1  10’ ±45’ (45’ or less) 1  05’±45’ (45’ or less) Steering axis inclination 13 05’ ±45’ 1300’±45’ HINT: Camber, caster and steering axis inclination are not adjustable. If measurements are not within speci– fication, inspect the suspension parts for damaged and/or worn out parts and replace them as necessary. SA–5 SUSPENSION AND AXLE – WHEEL ALIGNMENT 4. INSPECT TOE–IN Toe–in (total): A+B 0 ± 0.2 (C–D 0 ± 2 mm, 0 ± 0.08 in.) If the toe–in is not within specification, adjust it at the tie rod end. 5. ADJUST TOE–IN (a) Remove the boot clamps. (b) Loosen the tie rod end lock nuts. (c) Turn the left and right tie rod ends an equal amount to adjust the toe–in. HINT: Ensure that the lengths of the left and right tie rod end length are the same. Tie rod end length difference: 1.5 mm (0.059 in.) or less (d) Torque the tie rod end lock nuts. Torque: 74 N⋅m (750 kgf⋅cm, 54 ft⋅lbf) (e) Place the boot on the seat and install the clamp. HINT: Make sure that the boots are not twisted. 7. INSPECT WHEEL ANGLE Wheel angle: SEDAN/COUPE: Tire size Inside wheel Outside wheel (reference) P195/70R14 37 20’± 2 32 10’ P205/65R15 3600’ ± 2 31 15’ WAGON: Tire size Inside wheel Outside wheel (reference) P195/70R14 3720’ ± 2 32 15’ P205/65R15 36 00’ ± 2 31  20’ If the wheel angles differ from specification, check the left and right tie rod end length. Tie rod end length difference: 1.5 mm (0.059 in.) or less SA–6 SUSPENSION AND AXLE – WHEEL ALIGNMENT REAR WHEEL ALIGNMENT 7. MEASURE VEHICLE HEIGHT Rear vehicle height: SEDAN/COUPE: Tire size P 19 5/78 R 14 Rear 262 mm (10.31 in.) P205/65R15 267 mm (10.51 in.) WAGON: Tire size P195/70R14 Rear 272 mm (10.71 in.) P205/65 R15 277 mm (10.91 in.) Measuring point: Measure from the ground to the center of the strut rod mounting bolt. NOTICE: Before inspecting the wheel alignment, adjust the vehicle height to specification. If the vehicle height is not standard, try to adjust it by pushing down on or lifting the body. 2. INSTALL CAMBER – CASTER – KINGPIN GAUGE ONTO VEHICLE OR POSITION VEHICLE ON WHEEL ALIGNMENT TESTER Follow the specific instructions of the equipment manufacturer. 3. INSPECT CAMBER Camber (Left–right error) SEDAN/COUPE – 0
26’ ± 45’ (45’ or less) WAGON –0
15’ ± 45’ (45’ or less) HINT: Camber is not adjustable, if measurement is not within specification, inspect and replace the suspen– sion parts as necessary. 4. INSPECT TOE–IN Toe–in (total): A+B 0.4
± 0.2
(C – D 4 ± 2 mm, 0.16 ± 0.08 in.) If the toe–in is not within the specification, adjust it at the No.2 lower suspension arm. SA–7 SUSPENSION AND AXLE – WHEEL ALIGNMENT 5. ADJUST TOE–IN (a) Measure the length of the left and right No.2 lower suspension arm. Left–right difference: 1 mm (0.04 in.) or less If the left–right difference is greater than the specifi– cation, adjust the length. (b) Loosen the lock nuts. (c) Turn the left and right adjusting tubes an equal amount to adjust toe–in. HINT: One full turn of each adjusting tube will adjust the toe–in by about O.6
(6.7 mm, 0.264 in.). (d) Torque the lock nuts. Torque: 56 N⋅m (570 kgf⋅cm, 41 ft⋅lbf) SA–8 SUSPENSION AND AXLE – FRONT AXLE FRONT AXLE DESCRIPTION The wheel bearings are double–row angular ball bearings combined with the oil seal. They have a small rolling resistance and are free from maintenance. The preload of the bearings can be determined only by tightening the axle hub nut to a specified torque, improving serviceability. SA–9 SUSPENSION AND AXLE – FRONT AXLE PREPARATION SST (SPECIAL SERVICE TOOLS) 09310–35010 Countershaft Bearing Replacer Bearing removal Axle shaft installation 09316–60010 Transmission & Transfer Bearing Replacer Dust deflector Installation (09316–00010) Replacer Pipe (09316–00040) Replacer “C“ 09520–00031 Rear Axle Shaft Puller 09608–32010 Steering Knuckle Oil Seal Replacer Bearing installation Axle hub installation Dust deflector installation 09628–10011 Ball Joint Puller Hub bolt removal 09628–62011 BaII ,Joint Puller 09950–00020 Bearing Remover RECOMMENDED TOOLS 09905–00013 Snap Ring Pliers EQUIPMENT Dial indicator Torque wrench SA–10 SUSPENSION AND AXLE – FRONT AXLE FRONT AXLE HUB COMPONENTS SA–11 SUSPENSION AND AXLE – FRONT AXLE STEERING KNUCKLE WITH AXLE HUB REMOVAL 1. JACK UP VEHICLE, REMOVE FRONT WHEEL 2. CHECK BEARING BACKLASH AND AXLE HUB DE– VIATION (a) Remove the 2 brake caliper set bolts. (b) Hang up the brake caliper using wire, etc. (c) Remove the disc. (d) Place the dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 in.) If greater than the specified maximum, replace the bearing. (e) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.05 mm (0.0020 in.) If greater than the specified maximum, replace the axle hub. 3. REMOVE DRIVE SHAFT LOCK NUT (a) Install the disc and brake caliper. (b) Remove the cotter pin and lock cap. (c) While applying the brakes, remove the nut. (d) Remove the brake caliper and disc. 4. w/ ABS: REMOVE ABS SPEED SENSOR Remove the ABS speed sensor from the steering knuckle. 5. LOOSEN NUTS ON LOWER SIDE OF SHOCK ABS– ORBER HINT: Do not remove the bolts. SA–12 SUSPENSION AND AXLE – FRONT AXLE 6. DISCONNECT TIE ROD END FROM STEERING KNU– CKLE (a) Remove the cotter pin and remove the nut. (b) Using SST, disconnect the tie rod end from the steer– ing knuckle. SST 09628–62011 7. DISCONNECT LOWER BALL JOINT FROM LOWER ARM Remove the bolt and the two nuts. 8. REMOVE STEERING KNUCKLE WITH AXLE HUB (a) Remove the 2 nuts and bolts on lower side of the shock absorber. (b) Remove the steering knuckle with axle hub. FRONT AXLE HUB DISASSEMBLY 1. REMOVE DUST DEFLECTOR Using a screwdriver, remove the dust deflector. SA–13 SUSPENSION AND AXLE – FRONT AXLE 2. REMOVE LOWER BALL JOINT (a) Remove the cotter pin and nut. (b) Using SST, remove the lower ball joint. SST 09628–62011 3. REMOVE AXLE HUB (a) Using SST, remove the axle hub. SST 09520–00031 (b) Using SST and a press, remove the inner race (outside) from the axle hub. SST 09950–00020 4. REMOVE DUST COVER Remove the 4 bolts and dust cover–. 5. REMOVE BEARING FROM STEERING KNUCKLE (a) Using snap ring pliers, remove the snap ring. SA–14 SUSPENSION AND AXLE – FRONT AXLE (b) Place the inner race on the outside of the bearing. (c) Using SST and a hammer, remove the bearing. SST 09310–35010 FRONT AXLE HUB ASSEMBLY 1. INSTALL BEARING (a) Using SST and a press, install a new bearing to the steering knuckle. SST 09608–32010 (b) Using snap ring pliers, install a new snap ring. 2. INSTALL DUST COVER Place the dust cover and torque the 4 bolts. Torque: 8.3 N⋅m (85 kgf⋅cm, 74 in.⋅Ibf) 3. INSTALL FRONT AXLE HUB Using SST and a press, install the axle hub. SST 09310 – 35010, 09608 – 32010 SA–15 SUSPENSION AND AXLE – FRONT AXLE 4. INSTALL LOWER BALL JOINT (a) Install the lower ball joint and torque the nut. Torque: 123 N⋅m (1,250 kgf⋅cm. 90 ft⋅lbf) (b) Install a new cotter pin. 5. INSTALL DUST DEFLECTOR Using SST and a hammer, install a new dust deflector. SST 09316–60010(09316–00010, 09316–00040) 09608–32010 HINT: Align the holes for the ABS speed sensor in the dust deflector and steering knuckle. STEERING KNUCKLE WITH AXLE HUB INSTALLATION 1. INSTALL STEERING KNUCKLE (a) Place the steering knuckle and temporarily install the 2 bolts and nut on lower side of shock absorber. HINT: Coat the threads of nuts with engine oil. (b) Connect the lower ball joint to the lower arm and tighten the bolt and nuts. Torque: 127 N⋅m (1,300 kgf⋅cm. 94 ft⋅lbf) 2. CONNECT TIE ROD END TO STEERING KNUCKLE (a) Connect the tie rod end to the steering knuckle and tighten the nut. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) (b) Install a new cotter pin. SA–16 SUSPENSION AND AXLE – FRONT AXLE 3. TORQUE BOLTS ON LOWER SIDE OF SHOCK ABS– ORBER Torque: 211 N⋅m (2,150 kgf⋅cm, 156 ft⋅Ibf) 4. w/ ABS: INSTALL ABS SPEED SENSOR Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅Ibf) 5. INSTALL FRONT BRAKE CALIPER (a) Install the disc. (b) Install the brake caliper. Torque: 107 N⋅m (1,090 kgf⋅cm, 79 ft⋅lbf) 6. INSTALL DRIVE SHAFT LOCK NUT (a) While applying the brakes, install the nut. Torque: 294 N⋅m (3,000 kgf⋅cm, 217 ft⋅lbf) (b) Install the lock cap and a new cotter pin. 7. INSTALL FRONT WHEEL AND LOWER VEHICLE Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 8. INSPECT FRONT WHEEL ALIGNMENT (SEE PAGE SA–4) HUB BOLT REPLACEMENT 1. JACK UP VEHICLE AND REMOVE FRONT WHEEL 2. REMOVE FRONT BRAKE CALIPER AND DISC 3. REMOVE HUB BOLT Using SST, remove the hub bolt. SST 09628 –10011 SA–17 SUSPENSION AND AXLE – FRONT AXLE 4. INSTALL HUB BOLT (a) Install washer and nut to the hub bolt as shown in the illustration. (b) Install the hub bolt with torquing the nut. Install the hub bolt with torquing the nut. 5. INSTALL FRONT DISC AND BRAKE CALIPER Torque: 107 N⋅m (1,090 kgf⋅cm, 79 ft⋅Ibf) 6. INSTALL FRONT WHEEL AND LOWER VEHICLE Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅Ibf) SA–18 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1mz–fe) FRONT DRIVE SHAFT (1 MZ–FE) DESCRIPTION The drive shaft has a cross–groove type CVJ (Constant Velocity Joint) on the differential side and Rzeppa type CVJ on the wheel side. SA–19 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) PREPARATION SST (SPECIAL SERVICE TOOLS) 09608–1 6041 Front Hub Bearing Adjusting Tool (09608–02020) Bolt & Nut (09608–02040) Retainer 09628–62011 Ball ,Joint Puller Tie rod end 09726–10010 Lower Suspension Arm Bushing Remover & Replacer (09726–00030) Spacer Drive shaft inboard joint 09923–00020 Hexagon 8 mm Wrench 09950–00020 Bearing Remover Center drive shaft dust cover 09521–24010 Drive Shaft Boot Clamping Tool 09240–00020 Wire Gauge Set 09242–00190 Wire Gauge RECOMMENDED TOOLS 09905–00012 Snap Ring No. 1 Expander Corrected 6/07/01 – MH For removing and installing snap ring SA–20 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) EQUIPMENT Torque wrench LUBRICANT Drive shaft Toyota type Item Outboard joint grease Inboard joint grease Capacity 120–130 g (4.2–4.6 oz.) 133–153 g (4.7–5.4 oz.) SSM (SPECIAL SERVICE MATERIALS) 08826–00801 Seal Packing 1121, THREE BOND 1121 or equivalent Drive shaft inboard joint cover SA–21 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) FRONT DRIVE SHAFT COMPONENTS SA–22 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) FRONT DRIVE SHAFT REMOVAL NOTICE: The hub bearing could be damaged if it is sub– jected to the vehicle weight, such as when moving the vehicle with the drive shaft removed. Therefore, if it is absolutely necessary to place the vehi– cle weight on the hub bearing, first support it with SST. SST 09608–16041(09608–02020, 09608–02040) 1. REMOVE FRONT FENDER APRON SEAL 2. REMOVE COTTER PIN, LOCK NUT CAP AND LOCK NUT (a) Remove the cotter pin and lock nut cap. (b) Loosen the bearing lock nut while depressing the brake pedal. 3. DRAIN TRANSAXLE OIL 4. DISCONNECT TIE ROD END FROM STEERING KNU– CKLE (a) Remove the cotter pin and nut from the tie rod end. (b) Using SST, disconnect the tie rod end from the steer– ing knuckle. SST 09628–62011 5. DISCONNECT STABILIZER BAR LINK FROM LOWER ARM Remove the nut and disconnect the stabilizer bar link from lower arm. SA–23 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) 6. DISCONNECT STEERING KNUCKLE FROM LOWER BALL JOINT (a) Remove the bolt and the 2 nuts. (b) Disconnect the steering knuckle from the lower ball joint. 7. LOOSEN 6 BOLTS HOLDING DRIVE SHAFT TO DIF– FERENTIAL SIDE GEAR SHAFT OR CENTER DRIVE SHAFT (a) Place matchmarks on the drive shaft and side gear shaft or center drive shaft. NOTICE: Do not use a punch to mark the matchmarks. Use paint, etc. (b) Using SST, loosen the 6 hexagon bolts while depress– ing the brake pedal. SST 09923 – 00020 HINT: Do not remove the bolts, leave them finger tight to avoid drop ping the drive shaft. 8. DISCONNECT DRIVE SHAFT FROM AXLE HUB (a) Using a plastic hammer, discontinued the drive shaft from the axle hub. NOTICE: Cover the drive shaft boot with cloth to protect it from damage. (b) Push the front axle hub toward the outside of the vehicle, and separate the drive shaft from the axle hub. 9. REMOVE LH DRIVE SHAFT (a) Using hub nut wrench and hammer handle or equiva– lent, pull out the drive shaft as shown. SA–24 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) (b) Using a screwdriver, remove the snap ring. 10. REMOVE RH DRIVE SHAFT (a) Remove the bearing lock bolt. (b) Using pliers, remove the snap ring, and pull out the drive shaft. SA–25 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) FRONT DRIVE SHAFT INSTALLATION 1. INSTALL LH DRIVE SHAFT (a) Using pliers, install a new snap ring. (b) Coat gear oil to the side gear shaft and differential case sliding surface. (c) Using a brass bar and hammer, tap in the drive shaft until it makes contact with the pinion shaft. HINT: • Before installing the drive shaft, set the snap ring opening side facing downward. • Whether or not the side gear shaft is making contact with the pinion shaft can be known by the sound or feeling when driving it in. 2. CHECK INSTALLATION OF LH DRIVE SHAFT (a) Check that there is 2–3 mm (0.08–0.12 in.) of play in the axial direction. (b) Check that the drive shaft can not be removed by hand. 3. INSTALL RH DRIVE SHAFT (a) Coat gear oil to the inboard joint and differential sliding surface. (b) Install the drive shaft to the transaxle through the bearing bracket. NOTICE: Do not damage the oil seal lip. (c) Using pliers, install a new snap ring. (d) Install a new bearing lock bolt and tighten it. Torque: 32 N⋅m (330 kgf⋅cm, 24 ft⋅lbf) SA–26 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) 4. CONNECT DRIVE SHAFT TO AXLE HUB Install the outboard joint side of the drive shaft to the axle hub. NOTICE: Do not damage the boot. 5. CONNECT STEERING KNUCKLE TO LOWER ARM Torque: 127 N⋅m (1,300 kgf⋅cm, 94 ft⋅lbf) 6. TIGHTEN6 HEXAGON BOLTS Using SST, tighten the6 hexagon bolts while depress– ing the brake pedal. SST 09043–88010 Torque: 65 N⋅m (660 kgf⋅cm, 48 ft⋅lbf) 7. CONNECT STABILIZER BAR LINK TO LOWER ARM Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) 8. CONNECT TIE ROD END TO STEERING KNUCKLE (a) Connect the tie rod end to the steering knuckle and torque the nut. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) (b) Install a new cotter pin. HINT: If the cotter pin hole does not line up, correct by tightening the nut by the smallest amount possible. SA–27 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) 9. INSTALL BEARING LOCK NUT, LOCK NUT CAP AND NEW COTTER PIN (a) Install and torque the bearing look nut Torque: 294 N⋅m (3,000 kgf⋅cm, 217 ft⋅lbf) (b) Install the lock nut cap and secure it with a new cotter pin. 10. FILL TRANSAXLE WITH GEAR OIL 11. INSTALL FRONT FENDER APRON SEAL 12. CHECK FRONT WHEEL ALIGNMENT FRONT DRIVE SHAFT DISASSEMBLY 1. CHECK DRIVE SHAFT (a) Check to see that there is no play in the inboard and outboard joints. (b) Check to see that the inboard joint slides smoothly in the thrust direction. (c) Check to see that there is no significant play in the radial direction of the inboard joint. (d) Check the boot for damage. 2. DISCONNECT CENTER DRIVE SHAFT OR SIDE GEAR SHAFT (a) Using SST, remove the 6 bolts and 3 washers, and disconnect the center drive shaft or side gear shaft from the drive shaft. SST 09923–00020 NOTICE: Do not compress the inboard boot. (b) Remove the joint end cover gasket from the drive shaft. (c) Use bolts, nuts and washers to keep the inboard joint together. NOTICE: Tighten the bolts by hand to avoid scratching the flange surface. SA–28 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) 3. TOYOTA TYPE: REMOVE INBOARD AND OUTBOARD JOINT BOOT CLAMPS Using a screwdriver, remove the inboard and outboard joint clamps. GKN TYPE: REMOVE INBOARD AND OUTBOARD JOINT BOOT CLAMPS (a) Using a boot clamp tool, draw hooks together and remove the clamps. (b) Using side cutters, cut the small boot clamps and remove them. 4. DISASSEMBLE INBOARD JOINT (a) Place matchmarks on the inboard joint and drive shaft. (b) Using a snap ring expander remove the snap ring. SA–29 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) (c) Using SST, a socket wrench and a press, remove the inboard joint from the drive shaft. SST 09726–10010(09726–00030) (d) Remove the bolts, nuts and washers. (e) Using a screwdriver and a hammer, pry around the whole perimeter of the inboard joint cover. (f) Using a screwdriver, remove the inboard joint from inboard joint cover. NOTICE: When lifting the inboard joint, hold onto the inner race and outer race. 5. REMOVE BOOTS Remove the inboard joint boot and outboard joint boot. 6. LH DRIVE SHAFT: DISASSEMBLE SIDE GEAR SHAFT Using a screwdriver, remove the dust cover. 7. RH DRIVE SHAFT: DISASSEMBLE CENTER DRIVE SHAFT (a) Using a press, press out the transaxle side dust cover. SA–30 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) (b) Using SST and a press, press out the drive shaft side dust cover. SST 09950–00020 (c) Using snap ring pliers, remove the snap ring. (d) Using a press, press out the bearing. (e) Remove the snap ring. FRONT DRIVE SHAFT ASSEMBLY 1. RH DRIVE SHAFT: ASSEMBLE CENTER DRIVE SHAFT (a) Install a new snap ring to the center drive shaft. (b) Using a press and extension bar, press in a new bearing. (c) Using a snap ring expander, install a new snap ring. SA–31 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) (d) Using a press, press in a new drive shaft side dust cover. HINT: The clearance between the dust cover and the bearing should be kept in the range shown in the illustration. (e) Using a press, press in a new transaxle side dust cover. 2. LH DRIVE SHAFT: ASSEMBLE SIDE GEAR SHAFT Using a press, press in a new dust cover. 3. INSTALL NEW OUTBOARD JOINT BOOT AND NEW BOOT CLAMP HINT: • Before installing the boot, wrap vinyl tape around the spline of the shaft to prevent damaging the boot. • Temporarily install the new boot and new clamps to the outboard joint. 4. ASSEMBLE BOOT TO OUTBOARD JOINT Before assembling the boot, pack in grease. HINT: Use the grease supplied in the boot kit. Grease capacity: 135–155 g (4.8–5.5 oz.) 5. INSTALL NEW BOOT CLAMPS AND INBOARD JOINT BOOT Temporarily install the 2 new boot clamps and inboard joint boot. SA–32 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) 6. ASSEMBLE NEW INBOARD JOINT COVER (a) Clean contacting surfaces of any residual packing material using cleaner. (b) Apply seal packing to the inboard joint cover as shown in the illustration. Seal packing: Part No. 08826–00801. THREE BOND 1122 or equi– valent HINT: Avoid applying an excess amount to the sur– face. (c) Align the bolt holes of the cover with those of the inboard joint, then insert the hexagon bolts. (d) Use a plastic hammer to tap the rim of the inboard joint cover into place. Do this in the order shown, and repeat several times. (e) Use bolts, nuts and washers to keep the inboard joint together. NOTICE: Tighten the bolts by hand to avoid scratching the flange surface. 7. ASSEMBLE INBOARD JOINT (a) Align the matchmarks placed before disassembly. (b) Using a brass bar and hammer, tap the inboard joint onto the drive shaft. NOTICE: Check that the brass bar is touching the inner race, and not the cage. (c) Using a snap ring expander, install a new snap ring. NOTICE: Work carefully so that the outer race does not come off. SA–33 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) 8. ASSEMBLE INBOARD JOINT BOOT TO INBOARD JOINT Pack in grease to the inboard tulip and boot. HINT: Use the grease supplied in the boot kit. Grease capacity: 140–150 g (4.9–5.3 oz.) 9. ASSEMBLE BOOT CLAMPS TO BOTH BOOTS (a) Be sure the boots are in the shaft groove. (b) Ensure that the boots are not stretched or contracted when the drive shaft is at standard length. Drive shaft standard length: 452.35
2.0 mm (17.8090
0.079 in.) (c) Holding the clamp near the closing hooks, using pliers, position the holers in the clamp’s free end over the closing hooks. (d) Secure clamp by drawing the closing hooks together. (e) Check that the clamp at closed position is the same as that shown in the illustration. (f) Secure the clamp onto the boot. (g) Place SST onto the clamp SST 09521 – 24010 SA–34 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(1MZ–FE) (h) Tighten SST so that the clamp is pinched. HINT: Pinch the inboard side of the boot clamp, as shown in the illustration. NOTICE: Do not overtighten the SST. (i) Using SST, adjust the clearance of the clamp. SST 09240 – 00020 Clearance: 1.9 mm(0.0075 in.) or less 10. PACK IN GREASE TO CENTER DRIVE SHAFT OR SIDE GEAR SHAFT Pack grease into the center drive shaft or side gear shaft. Grease capacity: 50–60 g (1.8–2.1 oz.) HINT: Use the grease supplied in the boot kit. 11. CONNECT DRIVE SHAFT AND CENTER DRIVE SHAFT OR SIDE GEAR SHAFT (a) Remove the bolts, nuts and washers. (b) Align the matchmarks on the drive shaft and center drive shaft or side gear shaft. (c) Place a new gasket on the inboard joint. (d) Install the center drive shaft or side gear shaft to the drive shaft. NOTICE: When moving the drive shaft, do not compress the inboard boot. (e) Install the 3 washers and 6 hexagon bolts, and using SST, temporarily tighten them. SST 09923–00020 12. CHECK DRIVE SHAFT (a) Check to see that there is no play in the inboard joint and outboard joint. (b) Check to see that inboard joint slides smoothly in the thrust direction. SA–35 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5s–fe) FRONT DRIVE SHAFT (5S–FE) DESCRIPTION The drive has a tripod type CVJ (Constant Velocity Joint) on the differential side and Rzeppa type CVJ on the wheel side. SA–36 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) PREPARATION SST (SPECIAL SERVICE TOOLS) 0950fi–35010 Differential Drive Pinion Rear Bearing Replacer 09608–1fi041 Front Hub Bearing Adjusting Tool (09608–02020) Bolt & Nut (09608–02040) Retainer 09628–62011 Ball ,Joint Puller 09950–00020 Bearing Remover Tie rod end Center drive shaft dust cover 09521–24010 Drive Shaft Boot Clamping Tool 09240–00020 Wire Gauge Set (09242–00190) Wire Gauge RECOMMENDED TOOLS 09905–00012 Snap Ring No. 1 Expander EQUIPMENT Torque wrench For removing and installing snap ring SA–37 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) FRONT DRIVE SHAFT COMPONENTS SA–38 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) FRONT DRIVE SHAFT REMOVAL NOTICE: The hub bearing could be damaged if it is sub– jected to the vehicle weight, such as when moving the vehicle with the drive shaft removed. Therefore, if it is bearing first support it with SST. SST 09608–16041(09608–02020,09608–02040) 1. REMOVE FRONT FENDER APRON SEAL 2. REMOVE COTTER PIN, LOCK NUT CAP AND LOCK NUT (a) Remove the cotter pin and lock nut cap. (b) Loosen the bearing lock nut while depressing the brake pedal. 3. DRAIN TRANSAXLE OIL 4. DISCONNECT TIE ROD END FROM STEERING KNU– CKLE (a) Remove the cotter pin and nut from the steering knuckle. (b) Using SST, disconnect the tie rod end from the steer– ing knuckle. SST 09628–62011 5. DISCONNECT STABILIZER BAR LINK FROM LOWER ARM Remove the nut and disconnect the stabilizer bar link from lower arm. SA–39 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) 6. DISCONNECT STEERING KNUCKLE FROM LOWER BALL JOINT (a) Remove the bolt and the 2 nuts. (b) Disconnect the steering knuckle from lower ball joint. 7. DISCONNECT DRIVE SHAFT FORM AXLE HUB Using a plastic hammer, disconnect the drive shaft from the axle hub. NOTICE: Cover the drive shaft boot with cloth to protect it from damage. 8. REMOVE LH DRIVE SHAFT (a) Using hub nut wrench and hammer handle or an equivalent, pull out the drive shaft as shown. (b) Using a screwdriver, remove the snap ring. 9. REMOVE RH DRIVE SHAFT (a) Remove the bearing lock bolt. SA–40 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) (b) Using pliers, remove the snap ring, and pull out the drive shaft. FRONT DRIVE SHAFT INSTALLATION 1. INSTALL LH DRIVE SHAFT (a) Using a snap ring expander, install a new snap ring. (b) Coat gear oil to the inboard joint tulip and differential case sliding surface. (c) Using a brass bar and hammer, tap in the drive shaft until it makes contact with the pinion shaft. HINT: • Before installing the drive shaft, set the snap ring opening side facing downward. • Whether or not the drive shaft is making contact with the pinion shaft can be known by the sound or feeling when driving it in. 2. CHECK INSTALLATION OF LH DRIVE SHAFT (a) Check that there is 2–3 mm (0.08–0.12 in.) of play in the axial direction. (b) Check that the drive shaft can not be removed by hand. 3. INSTALL RH DRIVE SHAFT (a) Coat gear oil to the inboard joint and differential sliding surface. (b) Install the drive shaft to the transaxle through the bearing bracket. NOTICE: Do not damage the oil seal lip. (c) Using pliers, install a new snap ring. SA–41 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) (d) Install a new bearing lock bolt and tighten it. Torque: 32 N⋅m (330 kgf⋅cm, 24 ft⋅lbf) 4. CONNECT DRIVE SHAFT TO AXLE HUB Install the outboard joint side of the drive shaft to the axle hub. NOTICE: Do not damage the boot. 5. CONNECT STEERING KNUCKLE TO LOWER ARM Torque: 127 N⋅m (1,300 kgf⋅cm, 94 ft⋅lbf) 6. CONNECT STABILIZER BAR LINK TO LOWER ARM Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) 7. CONNECT TIE ROD END TO STEERING KNUCKLE (a) Connect the tie rod end to the steering knuckle and torque the nut. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) (b) Install a new cotter pin. HINT: (f the cotter pin hole does not line up, correct by tightening the nut by the smallest amount possible. SA–42 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) 8. INSTALL BEARING LOCK NUT, LOCK NUT CAP AND NEW COTTER PIN (a) Install and torque the bearing lock nut. Torque: 284 N⋅m (3,000 kgf⋅cm, 217 ft⋅lbf) (b) Install the lock nut cap and secure it with a new cotter pin. 9. FILL TRANSAXLE WITH FLUID 10. INSTALL FRONT FENDER APRON SEAL 11. CHECK FRONT WHEEL ALIGNMENT FRONT DRIVE SHAFT DISASSEMBLY 1. CHECK DRIVE SHAFT (a) Check to see that there is no play in the outboard joint. (b) Check to see that the inboard joint slides smoothly in the thrust direction. (c) Check to see that there is not significant play in the radial direction of the inboard joint. (d) Check for damage to boots. 2. TOYOTA TYPE: REMOVE INBOARD AND OUTBOARD JOINT BOOT CLAMPS (a) Using a screwdriver, remove the 4 boot clamps. (b) Slide the inboard joint boot toward the outboard joint. GKN TYPE: REMOVE INBOARD AND OUTBOARD JOINT BOOT CLAMPS (a) Using a boot clamp tool, draw hooks together and remove the 2 large clamps. SA–43 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) (b) Using side cutters, cut small boot clamp and remove them. (c) Slide the inboard joint toward the outboard joint. 3. DISASSEMBLE INBOARD JOINT TULIP (a) Place matchmarks on the tripod and inboard joint tulip or center drive shaft. NOTICE: Do not punch the marks. (b) Remove the inboard joint tulip or center drive shaft from the drive shaft. 4. REMOVE TRIPOD JOINT (a) Using a snap ring expander remove the snap ring. (b) Using a snap ring expander, temporarily, slide the snap ring toward the outboard joint side. (c) Place matchmarks on the drive shaft and tripod. (d) Using a brass bar and a hammer, remove the tripod joint from the drive shaft. SA–44 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) (e) Using a snap ring expander, remove the snap ring. 5. REMOVE INBOARD AND OUTBOARD JOINT BOOTS Slide out the two boots. NOTICE: Do not disassemble the outboard joint. 6. REMOVE DUST COVER LH Drive Shaft: Using SST and a press, press out the dust cover from the inboard joint tulip. SST 09950–00020 RH Drive Shaft: Using a press, press out the dust cover from the center drive shaft. 7. RH DRIVE SHAFT: DISASSEMBLE CENTER DRIVE SHAFT (a) Using SST and a press, press out the dust cover. SST 09950–00020 (b) Using a snap ring expander, remove the snap ring. SA–45 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) (c) Using a press, press out the bearing. (d) Remove the snap ring. FRONT DRIVE SHAFT ASSEMBLY 1. RH DRIVE SHAFT: ASSEMBLE CENTER DRIVE SHAFT (a) Install a new snap ring to the center drive shaft. (b) Using a steel plate and press, press in the bearing. (c) Using a snap ring expander, install a new snap ring. (d) Using SST, an extension bar and press, press in a new dust cover. SST 09506 – 35010 HINT: The clearance between the dust cover and the bearing should be kept in the range shown in the illustration. 2. INSTALL DUST COVER LH Drive Shaft: Using a press, install a new dust cover. SA–46 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) RH Drive Shaft: Using a steel plate and press, press in a new dust cover until the distance from the tip of the center drive shaft to the dust cover falls within the specifica– tion as shown in the illustration. 3. TEMPORARILY INSTALL OUTBOARD JOINT BOOT AND NEW BOOT CLAMPS Temporarily install the boot and 2 new boot clamps for the outboard joint to the drive shaft. HINT: Before installing the boot, wrap vinyl tape around the spline of the drive shaft to prevent damag– ing the boot. 4. TEMPORARILY INSTALL INBOARD JOINT BOOT AND NEW BOOT CLAMPS Temporarily install the boot and 2 new boot clamps for the inboard joint to the drive shaft. 5. INSTALL TRIPOD JOINT (a) Using a snap ring expander, install a new snap ring. (b) Place the beveled side of the tripod joint axial spline toward the outboard joint. (c) Align the matchmarks placed before removal. SA–47 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) (d) Using a brass bar and hammer, tap in the tripod joint to the drive shaft. NOTICE: Do not tap the roller. (e) Using a snap ring expander, install a new snap ring. 6. INSTALL BOOT TO OUTBOARD JOINT Before assembling the boot, fill grease into the out– board joint and boot. HINT: Use the grease supplied in the boot kit. Grease capacity: TOYOTA Type: 120–130 g (4.2–4.6 oz.) GKN Type: 140–160 9 (4.9–5.6 oz.) Grease color: Black 7. INSTALL INBOARD JOINT TULIP TO FRONT DRIVE SHAFT (a) Pack in the grease to the boot and inboard joint tulip. HINT:– Use the grease supplied in the boot kit. Grease capacity: TOYOTA Type: 232–242 g (8.2–8.5 oz.) GKN Type: 185–215 g (6.5–7.6 oz.) Grease color: Yellow ocher SA–48 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) (b) Align the matchmarks placed before removal, and install the inboard joint tulip to the drive shaft. (c) Install the boot to the inboard joint tulip. S. TOYOTA TYPE: ASSEMBLE BOOT CLAMPS TO BOTH BOOTS (a) Be sure the boot is in the shaft groove. (b) Ensure that the boot is not stretched or contracted when the drive shaft is at standard length. Drive shaft standard length: LH 608.1 ±5.0 mm (23.941±0.197 in.) RH 866.2±5.0 mm (34.102±0.197 in.) (c) Using a screwdriver, bend the band and lock it as shown in the illustration. GKN TYPE: ASSEMBLE BOOT CLAMPS TO BOTH BOOT (a) Be sure the boots are in the shaft groove. (b) Ensure that the boot is not stretched or contracted when the drive shaft is at standard length. Drive shaft standard length: LH609Z±2.0 mm (23.984±0.079 in.) RH 880.8±2.0 mm (34.677±0.079 in.) (c) Using a boot clamp tool, place pincer jaws in closing hooks of large clamps. (d) Secure clamp by drawing closing hooks together. SA–49 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) (e) Check that the clamp at closed position is the same as in the illustration. (f) Secure the clamp onto the boot. (g) Place SST onto the clamp. SST 09521 – 24010 (h) Tighten SST so that the clamp is pinched. HINT: Pinch the inboard side of the boot clamp, as shown in the illustration. NOTICE: Do not overtighten the SST. (i) Using SST, adjust the clearance of the clamp. SST 09240 – 00020 Clearance: 1.9 mm (0.075 in.) or less Corrected 12/27/93 SA–50 SUSPENSION AND AXLE – FRONT SUSPENSION FRONT SUSPENSION DESCRIPTION The front suspension is MacPherson strut type suspension with L–shape lower arm. SA–51 SUSPENSION AND AXLE – FRONT SUSPENSION PREPARATION SST (SPECIAL SERVICE TOOLS) 09316–60010 Transmission & Transfer Bearing Replacer Dust deflector installation (09316–00010) Replacer Pipe (09316–00040) Replacer ’C’ 09608–32010 Steering Knuckle Oil Seal Replacer 09628–62011 Ball Joint Puller 09727–00045 Arm Set “B” 09727–30020 Coil Spring Compressor 09729–22031 Front Spring Upper Seat Holder RECOMMENDED TOOLS 09025–00010 Small Torque Wrench EQUIPMENT Torque wrench Dust deflector installation SA–52 SUSPENSION AND AXLE – FRONT SUSPENSION FRONT SHOCK ABSORBER COMPONENTS SA–53 SUSPENSION AND AXLE – FRONT SUSPENSION FRONT SHOCK ABSORBER REMOVAL 1. JACK UP VEHICLE AND REMOVE FRONT WHEEL 2. REMOVE BRAKE HOSE AND ABS SPEED SENSOR WIRE (W/ ABS) FROM SHOCK ABSORBER 3. DISCONNECT SHOCK ABSORBER FROM STEERING KNUCKLE Remove the 2 nuts and bolts and disconnect the shock absorber from the steering knuckle. 4. REMOVE SHOCK ABSORBER WITH COIL SPRING (a) Remove the 3 nuts on upper side of the shock ab– sorber. (b) Remove the shock absorber with coil spring. 5. REMOVE COIL SPRING (a) Using SST, compress the coil spring. SST 09727–00045,09727–30020 NOTICE: When holding the shock absorber with the coil spring removed, do not hold it by the spring lower seat. Also, do not knock the spring lower seat. (b) Install a bolt and 2 nuts to the bracket at the lower portion of the shock absorber and secure it in a vise. SA–54 SUSPENSION AND AXLE – FRONT SUSPENSION (c) Using SST to hold the upper support remove the nut. SST 09729–22031 (d) Remove the following parts. • Suspension upper support • Upper insulator • Coil spring • Spring bumper • Lower insulator NOTICE: Do not disassemble the spring lower seat. FRONT SHOCK ABSORBER INSPECTION 1. INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sounds. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When discarding the shock absorber, use the following procedure. FRONT SHOCK ABSORBER DISPOSAL 1. FULLY EXTEND SHOCK ABSORBER ROD 2. DRILL HOLE TO REMOVE GAS FROM CYLINDER Using a drill, make a hole in the cylinder as shown to remove the gas inside. CAUTION: The gas coming out is harmless, but be careful of chips which may fly up when drilling. SA–55 SUSPENSION AND AXLE – FRONT SUSPENSION FRONT SHOCK ABSORBER INSTALLATION 7. INSTALL LOWER INSULATOR ONTO SHOCK ABS– ORBER 2. INSTALL SPRING BUMPER TO PISTON ROD 3. INSTALL COIL SPRING (a) Using SST, compress the coil spring. SST 09727–00045,09727–30020 (b) Install the coil spring to the shock absorber. HINT: Fit the lower end of the coil spring into the gap of the lower seat. 4. INSTALL UPPER INSULATOR AND UPPER SUP– PORT (a) Install the upper insulator to the upper support. SA–56 SUSPENSION AND AXLE – FRONT SUSPENSION (b) Install the upper support to the piston rod. (c) Using SST to hold the upper support, install a new nut. SST 09729–20031 Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) (d) Rotate the upper support so that the lowest bolt on the upper support is aligned with the projection part of the spring lower seat shown in the illustration. (e) Remove the SST. HINT: After removing SST, again check the direction of the upper support. 5. INSTALL SHOCK ABSORBER WITH COIL SPRING Place the shock absorber and install the 3 nuts. Torque: 80 N⋅m (820 kgf⋅cm, 59 ft⋅lbf) 6. CONNECT SHOCK ABSORBER TO STEERING KNU– CKLE (a) Coat the threads of the nuts with engine oil. (b) Install the 2 bolts and nuts. Torque: 211 N⋅m (2,150 kgf⋅cm, 156 ft⋅lbf) SA–57 SUSPENSION AND AXLE – FRONT SUSPENSION 7. INSTALL BRAKE HOSE AND ABS SPEED SENSOR WIRE (W/ ABS) TO SHOCK ABSORBER Brake hose Torque: 29 N⋅m (300 kgf⋅cm, 22 ft⋅lbf) ABS wire Torque: 5.4 N⋅m (55 kgf⋅cm, 48 in.⋅lbf) 8. INSTALL FRONT WHEEL AND LOWER VEHICLE Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) 9. INSPECT FRONT WHEEL ALIGNMENT (See page SA–4) SA–58 SUSPENSION AND AXLE – FRONT SUSPENSION LOWER SUSPENSION ARM COMPONENTS SA–59 SUSPENSION AND AXLE – FRONT SUSPENSION LOWER ARM REMOVAL 1. JACK UP VEHICLE AND REMOVE FRONT WHEEL 2. REMOVE FRONT FENDER APRON SEAL 3. REMOVE DRIVE SHAFT LOCK NUT (a) Remove the cotter pin and lock cap. (b) While applying the brakes, remove the nut. 4. DISCONNECT TIE ROD END FROM STEERING KNU– CKLE (a) Remove the cotter pin and remove the nut. (b) Using SST, disconnect the tie rod end from the steer– ing knuckle. SST 09628–62011 5. REMOVE LEFT AND RIGHT STABILIZER END BRA– CKETS FROM LOWER ARMS 6. DISCONNECT LOWER ARM FROM LOWER BALL JOINT Remove the bolt and 2 nuts. SA–60 SUSPENSION AND AXLE – FRONT SUSPENSION 7. REMOVE DRIVE SHAFT PROM AXLE HUB (a) Remove the drive shaft from the axle hub. (b) Hang up the drive shaft using wire, etc. NOTICE: Be careful not to damage the drive shaft boot and ABS sensor rotor. 8. REMOVE LOWER ARM (a) Remove the 2 bolts on front side of the lower arm. (b) Remove the bolt and nut on rear side of the lower arm. (c) Remove the lower arm. (d) Remove the lower arm bushing stopper from the lower arm shaft. LOWER ARM INSTALLATION 1. INSTALL LOWER ARM (a) Place the lower arm and temporarily install the rear side bolt and nut SA–61 SUSPENSION AND AXLE – FRONT SUSPENSION (b) Install the lower arm bushing stopper to the lower arm shaft. (c) Install the 2 bolts on the front side of the lower arm. Torque: 206 N⋅m (2,100 kgf⋅cm, 152 ft⋅lbf) (d) Tighten the bolt on rear side of the lower arm. Torque: 206 N⋅m (2,100 kgf⋅cm, 152 ft⋅lbf) 2. INSTALL DRIVE SHAFT TO AXLE HUB 3. CONNECT LOWER ARM TO LOWER BALL JOINT Install the bolt and 2 nuts. Torque: 127 N⋅m (1,300 kgf⋅cm, 94 ft⋅lbf) 4. INSTALL LEFT AND RIGHT STABILIZER END BRA– CKETS TO LOWER ARMS Torque: 56 N⋅m (570 kgf⋅cm, 41 ft⋅lbf) SA–62 SUSPENSION AND AXLE – FRONT SUSPENSION 5. CONNECT TIE ROD END TO STEERING KNUCKLE (a) Connect the tie rod end to the steering knuckle and tighten the nut. Torque: 49 N⋅m (500 kgf⋅cm. 36 ft⋅lbf) (b) Install a new cotter pin. 6. INSTALL DRIVE SHAFT LOCK NUT (a) While applying the brakes, install the nut. Torque: 294 N⋅m (3,000 kgf⋅cm, 217 ft⋅lbf) (b) Install the lock cap and a new cotter pin. 7. INSTALL FRONT FENDER APRON SEAL 8. INSTALL FRONT WHEEL AND LOWER VEHICLE Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅Ibf) 9. INSPECT FRONT WHEEL ALIGNMENT (See page SA–4) SA–63 SUSPENSION AND AXLE – FRONT SUSPENSION LOWER BALL JOINT COMPONENTS SA–64 SUSPENSION AND AXLE – FRONT SUSPENSION LOWER BALL JOINT REMOVAL 1. REMOVE STEERING KNUCKLE WITH AXLE HUB (See page SA–11) 2. REMOVE LOWER BALL JOINT (a) Using a screwdriver, remove the dust deflector. (b) Remove the cotter pin and nut. (c) Using SST, remove the lower ball joint. SST 09628–62011 LOWER BALL JOINT INSPECTION 1. INSPECT BALL JOINT FOR ROTATION CONDITION (a) As shown, flip the ball joint stud back and forth 5 times before installing the nut. (b) Using a torque gauge, turn the nut continuously one turn per 2–4 seconds and take the torque reading on the 5th turn. Turning torque: 1.0–2.9 N⋅m (10–30 kgf⋅cm, 8.7–26 in.⋅lbf) LOWER BALL JOINT INSTALLATION 1. INSTALL LOWER BALL JOINT (a) Install the lower ball joint and tighten the nut. Torque: 123 N⋅m (1,250 kgf⋅cm, 90 ft⋅lbf) (b) Install a new cotter pin. SA–65 SUSPENSION AND AXLE – FRONT SUSPENSION 2. INSTALL DUST DEFLECTOR Using SST and a hammer, install a new dust deflector. SST 09316–60010 (09316–00010, 09316–00040) 09608–32010 HINT: Align the hoses for the ABS speed sensor in the dust deflector and steering knuckle. 3. INSTALL STEERING KNUCKLE WITH AXLE HUB (See page SA–15) SA–66 SUSPENSION AND AXLE – FRONT SUSPENSION STABILIZER BAR COMPONENTS SA–67 SUSPENSION AND AXLE – FRONT SUSPENSION STABILIZER BAR REMOVAL 1. JACK UP VEHICLE AND REMOVE LEFT AND RIGHT FRONT WHEELS 2. REMOVE LEFT AND RIGHT FENDER APRON SEALS 3. DISCONNECT LEFT AND RIGHT TIE ROD ENDS FROM STEERING KNUCKLES (a) Remove the cotter pin and nut. (b) Using SST, disconnect the tie rod end from the steer– ing knuckle. SST 09628–62011 4. REMOVE LEFT AND RIGHT STABILIZER BAR LINKS 5. REMOVE LEFT AND RIGHT STABILIZER BAR BUSH– INGS (a) Remove the left and right bushing retainers. (b) Remove the stabilizer bar bushings. 6. REMOVE EXHAUST FRONT PIPE 5S–FE Engine: (See page EG–139) 1 MZ–FE Engine: (See page EG–188) 7. REMOVE STEERING GEAR BOX MOUNTING BOLTS AND NUTS SA–68 SUSPENSION AND AXLE – FRONT SUSPENSION 8. REMOVE STABILIZER BAR HINT: Lift the steering gear box and remove the stabi– lizer bar. STABILIZER BAR LINK INSPECTION 1. INSPECT BALL JOINT FOR ROTATION CONDITION (a) Flip the ball joint stud back and forth 5 times as shown in the illustration, before installing the nut. (b) Using a torque gauge, turn the nut continuously one turn every 2–4 seconds and take the torque reading on the fifth turn. Turning torque: 0.05–1.0 N⋅m (0.5–10 kgf⋅cm, 0.4–8.7 in.⋅lbf) If not within specification, replace the stabilizer bar link. STABILIZER BAR INSTALLATION 1. POSITION STABILIZER BAR HINT: Lift the steering gear box and position the stabilizer bar. 2. INSTALL STEERING GEAR BOX MOUNTING BOLTS AND NUTS Torque: 181 N⋅m (1.850 kgf⋅cm, 134 ft⋅lbf) 3. INSTALL EXHAUST FRONT PIPE SS–FE Engine: (See page EG–139) 1 MZ–FE Engine: (See page EG–189) SA–69 SUSPENSION AND AXLE – FRONT SUSPENSION 4. INSTALL LEFT AND RIGHT STABILIZER BAR BUSH– INGS (a) Install the stabilizer bar bushings. (b) Install the bushing retainers and bolts. Torque: 19 N⋅m (195 kgf⋅cm, 14 ft⋅lbf) 5. INSTALL LEFT AND RIGHT STABILIZER BAR LINKS Torque: 39 N⋅m (400 kgf⋅cm. 29 ft⋅Ibf) 6. CONNECT LEFT AND RIGHT TIE ROD ENDS TO STEERING KNUCKLES (a) Connect the tie rod end to the steering knuckle and tighten the nut. Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) (b) Install a new cotter pin. 7. INSTALL LEFT AND RIGHT FENDER APRON SEALS 8. INSTALL FRONT WHEELS AND LOWER VEHICLE Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅Ibf) SA–70 SUSPENSION AND AXLE – REAR AXLE REAR AXLE DESCRIPTION The rear axle uses oil–sealed double–row angular ball bearings for wheel bearings. There is no need for bearing grease maintenance or preload adjustment. SA–71 SUSPENSION AND AXLE – REAR AXLE PREPARATION SST (SPECIAL SERVICE TOOLS) EQUIPMENT Dial indicator Torque wrench 09608–32010 Steering Knuckle oil Seal Replacer Axle hub installation (w/o A8S) 09628–10011 Ball Joint Puller Hub bolt removal 09636–20010 Upper Ball Joint Dust Cover Replacer Axle hub installation (w/o ASS) 09950–20017 Universal Puller (w/o ABS) SA–72 SUSPENSION AND AXLE – REAR AXLE REAR AXLE HUB COMPONENTS SA–73 SUSPENSION AND AXLE – REAR AXLE REAR AXLE HUB REMOVAL 1. JACK UP VEHICLE AND REMOVE REAR WHEEL 2. W/ DISC BRAKE: REMOVE BRAKE CALIPER AND DISC (a) Remove the 2 brake caliper set bolts. (b) Hang up the brake caliper using wire, etc. (c) Remove the disc. 3. w/ DRUM BRAKE: REMOVE BRAKE DRUM 4. CHECK BEARING BACKLASH AND AXLE HUB DE– VIATION (a) Place the dial indicator near the center of the axle hub and check the backlash in the bearing shaft direction. Maximum: 0.05 mm (0.0020 in.) If greater than the specified maximum, replace the bearing. (b) Using a dial indicator, check the deviation at the surface of the axle hub outside the hub bolt. Maximum: 0.47 mm (0.0028 in.) If greater then the specified maximum, replace the axle shaft and bearing. 6. REMOVE REAR AXLE HUB (a) Remove the 4 bolts and rear axle hub. (b) Remove the O–ring. SA–74 SUSPENSION AND AXLE – REAR AXLE REAR AXLE HUB DISASSEMBLY NOTICE: If equipped with ABS, do not disassemble the rear axle shaft and bearing. 1. REMOVE LOCK NUT (a) Using a hammer and chisel, release the nut caulking. (b) Remove the lock nut. 2. REMOVE AXLE SHAFT FROM BEARING (a) Using SST, remove the axle shaft from bearing. SST 09950 – 20017 (b) Using SST, remove the inner race (outside) from the axle shaft. SST 09950–20017 REAR AXLE HUB ASSEMBLY 1. INSTALL AXLE SHAFT TO BEARING (a) Using SST and a press, install the axle shaft to a new bearing. ST 09608–32010,09636–20010 (b) Install a new lock nut. Torque: 123 N⋅m (1250 kgf⋅cm, 90 ft⋅lbf) (c) Stake the lock nut. SA–75 SUSPENSION AND AXLE – REAR AXLE REAR AXLE HUB INSTALLATION 1. INSTALL REAR AXLE HUB (a) Install a new 0–ring. HINT: Coat the 0–ring with MP grease. (b) Install the rear axle hub with the 4 bolts. Torque: 80 N⋅m (820 kgf⋅cm, 59 ft⋅lbf) 2. w/ DISC BRAKE: INSTALL DISC AND BRAKE CALIPER. (a) Install the disc. (b) Install the brake caliper. Torque: 47 N⋅m (475 kgf⋅cm, 34 ft⋅lbf) 3. w/ DRUM BRAKE: INSTALL BRAKE DRUM 4. INSTALL REAR WHEEL AND LOWER VEHICLE Torque: 103 N⋅m (1,050 kgf⋅cm. 76 ft⋅lbf) HUB BOLT REPLACEMENT 1. JACK UP VEHICLE AND REMOVE REAR WHEEL 2. REMOVE REAR DISC OR DRUM 3. REMOVE HUB BOLT Using SST, remove the hub bolt. SST 09628–10011 4. INSTALL HUB BOLT Install washer– and nut to the hub bolt as shown in the illustration, and install the hub bolt by tightening the nut. 5. INSTALL REAR DISC OR DRUM 6. INSTALL REAR WHEEL AND LOWER VEHICLE Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅Ibf) SA–76 SUSPENSION AND AXLE – REAR AXLE REAR AXLE CARRIER COMPONENTS SA–77 SUSPENSION AND AXLE – REAR AXLE REAR AXLE CARRIER REMOVAL 1. REMOVE REAR AXLE HUB 2. w/ DRUM BRAKE: REMOVE BRAKE HOSE FROM SHOCK ABSORBER 3. REMOVE BACKING PLATE FROM REAR AXLE CAR– RIER Hang up the backing plate using wire, etc. 4. w/ ABS: REMOVE ABS SPEED SENSOR Remove the ABS speed sensor from rear axle carrier. 5. WAGON only: REMOVE LSPV SPRING Disconnect the LSPV spring from the lower arm. 6. REMOVE REAR AXLE CARRIER (a) Loosen the 3 nuts. HINT: Do not remove the bolts. SA–78 SUSPENSION AND AXLE – REAR AXLE (b) Remove the bolt and nut and disconnect the strut rod from the rear axle carrier. (c) Remove the 3 nuts and bolts. (d) Remove the rear axle carrier. REAR AXLE CARRIER INSTALLATION 1. INSTALL REAR AXLE CARRIER (a) Place the rear axle carrier and temporarily install the 3 bolts and nuts. (b) Connect the strut rod to the rear axle carrier. (c) Temporarily install the bolt and nut. (d) Torque the 3 nuts. Lower side of shock absorber: Torque: 255 N⋅m (2,600 kgf⋅cm, 188 ft⋅lbf) Lower arm: Torque: 181 N⋅m (1,850 kgf⋅cm, 134 ft⋅lbf) SA–79 SUSPENSION AND AXLE – REAR AXLE 2. w/ ABS: INSTALL ABS SPEED SENSOR Install the ABS speed sensor to the rear axle carrier. Torque: 7.8 N⋅m (80 kgf⋅cm, 69 in.⋅lbf) 3. WAGON only: INSTALL LSPV SPRING Connect the LSPV spring to the lower arm. Torque: 13 N⋅m (130 kgf⋅cm, 9.4 ft⋅Ibf) 4. INSTALL BACKING PLATE AND REAR AXLE HUB (a) Place the backing plate. (b) Install a new O–ring. (c) Install the rear axis hub. Torque: 80 N⋅m (820 kgf⋅cm, 59 ft⋅Ibf) 5. w/ DRUM BRAKE: INSTALL BRAKE LINE TO SHOCK ABSORBER Torque: 29 N⋅m (300 kgf⋅cm, 22 ft⋅lbf) 6. STABILIZE SUSPENSION (a) Install the rear wheel and lower the vehicle. (b) Bounce the vehicle up and down several times to stabilize the suspension. 7. TORQUE STRUT ROD BOLT (a) Jack up the vehicle and support the body. (b) Remove the rear wheel. (c) Support the rear axle carrier with a jack. (d) Torque the bolt. Torque: 113 N⋅m (1,150 kgf⋅cm, 83 ft⋅lbf) 8. INSTALL REAR WHEEL AND LOWER VEHICLE Torque: 103 N⋅m (1,050 kgf⋅cm, 76 ft⋅lbf) SA–80 SUSPENSION AND AXLE – REAR SUSPENSION REAR SUSPENSION DESCRIPTION The rear suspension is a dual–link strut independent suspension type composed of two lower arms in parallel at the side, and strut rods which extend forward. SA–81 SUSPENSION AND AXLE – REAR SUSPENSION PREPARATION SST (SPECIAL SERVICE TOOLS) 09727–30020 Coil Spring Compressor 09729–22031 Front Spring Upper Seat Holder RECOMMENDED TOOLS 09025–00010 Small Torque Wrench EQUIPMENT Torque wrench SA–82 SUSPENSION AND AXLE – REAR SUSPENSION REAR SHOCK ABSORBER COMPONENTS SA–83 SUSPENSION AND AXLE – REAR SUSPENSION REAR SHOCK ABSORBER REMOVAL 1. SEDAN/COUPE REMOVE REAR SEAT AND PACKAGE TRAY TRIM (SEE THE BO SECTION) WAGON: REMOVE REAR SIDE SEATBACK AND TONNEAU SIDE COVER (SEE PAGE BO SECTION) 2. JACK UP VEHICLE AND REMOVE REAR WHEEL 3. WAGON ONLY: DISCONNECT LSPV SPRING FROM LOWER ARM 4. REMOVE ABS SPEED SENSOR WIRE (w/ ABS) AND BRAKE HOSE FROM SHOCK ABSORBER 5. DISCONNECT STABILIZER BAR LINK FROM SHOCK ABSORBER 6. REMOVE SHOCK ABSORBER WITH COIL SPRING (a) Loosen the 2 nuts on lower side of shock absorber. SA–84 SUSPENSION AND AXLE – REAR SUSPENSION (b) Support the rear axle carrier with a jack. (c) Remove the 3 nuts of upper support. (d) Lower the rear axle carrier and remove the 2 bolts. (e) Remove the shock absorber with coil spring. 7. REMOVE COIL SPRING (a) Remove the cap. (b) Using SST, compress the coil spring. SST 09727–30020 (c) Install a bolt and 2 nuts to the bracket at the lower portion of the shock absorber and secure it in a visa. SA–85 SUSPENSION AND AXLE – REAR SUSPENSION (d) Using SST to hold the upper support, remove the nut. SST 09729–22031 (e) Remove the following parts. • Suspension upper support • Upper insulator • Coil spring • Spring bumper • Lower insulator REAR SHOCK ABSORBER INSPECTION INSPECT SHOCK ABSORBER Compress and extend the shock absorber rod and check that there is no abnormal resistance or unusual operation sounds. If there is any abnormality, replace the shock absorber with a new one. NOTICE: When discarding the shock absorber, use the following procedure. REAR SHOCK ABSORBER DISPOSAL 1. FULLY EXTEND SHOCK ABSORBER ROD 2. DRILL HOLE TO REMOVE GAS FROM CYLINDER Using a drill, make a hole in the cylinder as shown to remove the gas inside. CAUTION: The gas coming out is harmless, but be careful of chips which may fly up when drilling. REAR SHOCK ABSORBER INSTALLATION 1. INSTALL LOWER INSULATOR ONTO SHOCK ABS– ORBER SA–86 SUSPENSION AND AXLE – REAR SUSPENSION 2. INSTALL SPRING BUMPER TO PISTON ROD 3. INSTALL COIL SPRING (a) Using SST, compress the coil spring SST 09727–30020 (b) Install the coil spring to the shock absorber. HINT: Fit the lower end of the coil spring into the gap of the lower seat. 4. INSTALL UPPER INSULATOR AND UPPER SUP– PORT (a) Before installing the upper support and insulator, apply the lithium or silicon based grease as shown in the illustration. (b) Install the upper insulator to the upper support. HINT: Match the bolt of the upper support with the cut–off part of the insulator. SA–87 SUSPENSION AND AXLE – REAR SUSPENSION (c) Install the upper support to the piston rod. (d) Using SST to hold the upper support, install a new nut. SST 09729–22031 Torque: 49 N⋅m (500 kgf⋅cm, 36 ft⋅lbf) (e) Rotate the upper support and set it in the direction shown in the illustration. (f) Remove the SST. HINT: After removing SST, again check the direction of the upper support. (g) Install the cap. 5. INSTALL SHOCK ABSORBER WITH COIL SPRING Install the shock absorber and install the 3 nuts of upper support. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅Ibf) 6. CONNECT SHOCK ABSORBER TO REAR AXLE CAR– RIER (a) Coat the threads of the nuts with engine oil. (b) Install the 2 bolts and nuts. Torque: 255 N⋅m (2,600 kgf⋅cm, 188 ft⋅lbf) SA–88 SUSPENSION AND AXLE – REAR SUSPENSION 7. CONNECT STABILIZER BAR LINK TO SHOCK ABS– ORBER Torque: 64 N⋅m (650 kgf⋅cm, 47 ft⋅Ibf) 8. INSTALL ABS SPEED SENSOR WIRE (w/ ABS) AND BRAKE HOSE TO SHOCK ABSORBER Broke hose Torque: 29 N⋅m (300 kgf⋅cm, 22 ft⋅lbf) ABS wire Torque: 5.4 N⋅m (55 kgf⋅cm. 48 in.⋅lbf) 9. WAGON only: CONNECT LSPV SPRING FROM LOWER ARM Torque: 13 N⋅m (130 kgf⋅cm, 9 ft⋅lbf) 10. INSTALL REAR WHEEL AND LOWER VEHICLE Torque: 103 N⋅m (1,050 kgf⋅cm. 76 ft⋅lbf) 11. SEDAN/COUPE: INSTALL PACKAGE TRAY TRIM AND REAR SEAT (See the BO section) WAGON: INSTALL TONNEAU SIDE COVER AND REAR SIDE SEATBACK (See the BO section) SA–89 SUSPENSION AND AXLE – REAR SUSPENSION LOWER SUSPENSION ARM AND STRUT ROD COMPONENTS SA–90 SUSPENSION AND AXLE – REAR SUSPENSION 4^T–06 LOWER SUSPENSION ARM AND STRUT ROD REMOVAL 1. JACK UP VEHICLE AND REMOVE REAR WHEEL 2. REMOVE STRUT ROD (a) Remove the 2 bolts and nuts. (b) Remove the strut rod. 3. WAGON only: DISCONNECT LSPV SPRING FROM LOWER ARM 4. REMOVE NO.2 LOWER SUSPENSION ARM (a) Remove the 2 nuts and washers. (b) Remove the No.2 lower suspension arm. 5. REMOVE LEFT AND RIGHT STABILIZER BUSHING RETAINER 6. REMOVE EXHAUST CENTER PIPE AND TALE PIPE 5S–FE Engine: (See page EG1–139) 1MZ–FE Engine: (See page EG2–189) 7. REMOVE NO.1 LOWER SUSPENSION ARM (a) Support the suspension member with a jack. SA–91 SUSPENSION AND AXLE – REAR SUSPENSION (b) Remove the 6 nuts and the left and right suspension member lower stopper. (c) Lower the suspension member. (d) Remove the No. 1 lower suspension arm with the 2 bolts and the washer. NO.2 LOWER SUSPENSION ARM DISASSEMBLY 1. DISASSEMBLE NO.2 LOWER SUSPENSION ARM (a) Loosen the 2 lock nuts. (b) Turn the adjusting tube and disassemble the No.2 lower suspension arm. (c) Remove the lock nuts from the arms. NO.2 LOWER SUSPENSION ARM ASSEMBLY 1. ASSEMBLE NO.2 LOWER SUSPENSION ARM (a) Install the lock nuts to the arms. (b) Turn the adjusting tube and assemble the No.2 lower suspension arm. SA–92 SUSPENSION AND AXLE – REAR SUSPENSION HINT: When assembling the No.2 lower suspension arm, try to make dimensions A and B shown in the illustration as close as possible. Maximum difference: 3 mm (0.12 in.) (c) Adjust the No.2 lower suspension arm length by turn– ing the adjusting tube. Arm length: 584.2 mm (23.000 in.) (d) Temporarily tighten the 2 lock nuts. HINT: After adjusting the rear wheel alignment, torque the lock nuts. 401W–06 LOWER SUSPENSION ARM AND STRUT ROD INSTALLATION 1. INSTALL NO.1 LOWER SUSPENSION ARM Install the No. 1 lower suspension arm with the washer and the 2 bolts. HINT: Face the paint mark to the rear. 2. INSTALL SUSPENSION MEMBER TO BODY (a) Jack up the suspension member. (b) Install the suspension member lower supports and the 6 nuts. Nut A: Torque: 51 N⋅m (520 kgf⋅cm, 38 ft⋅lbf) Nut B: Torque: 38 N⋅m (390 kgf⋅cm, 28 ft⋅lbf) 3. INSTALL LEFT AND RIGHT STABILIZER BUSHING RETAINERS Torque: 19 N⋅m (195 kgf⋅cm, 14 ft⋅lbf) 4. INSTALL EXHAUST CENTER PIPE AND TALE PIPE 5S–FE Engine: (See page EG1–139) 1MZ–FE Engine: (See page EG2–189) SA–93 SUSPENSION AND AXLE – REAR SUSPENSION 5. INSTALL NO.2 LOWER SUSPENSION ARM (a) Install the No.2 lower suspension arm with the 3 washers. HINT: Face the paint mark to the rear. (b) Temporarily install the 2 lock nuts. 6. WAGON only: CONNECT LSPV SPRING TO LOWER ARM Torque: 13 N⋅m (130 kgf⋅cm, 9.4 ft⋅lbf) 7. INSTALL STRUT ROD Place the strut rod and temporarily install the 2 bolts and nuts. 8. TORQUE BOLTS AND NUTS (a) Torque the nut on outside of the lower arm. Torque: 181 N⋅m (1,850 kgf⋅cm, 134 ft⋅lbf) (b) Install the rear wheel and lower the vehicle. (c) Bounce the vehicle up and down several times to stabilize the suspension. (d) Jack up the vehicle and support the body with stands. (e) Remove the rear wheel. (f) Support the rear axle carrier with a jack. (g) Torque the nut on inside of lower arm. Torque: 181 N⋅m (1.850 kgf⋅cm, 134 ft⋅lbf) SA–94 SUSPENSION AND AXLE – REAR SUSPENSION (h) Torque the strut rod set bolts. Torque: 113 N⋅m (1,150 kgf⋅cm, 83 ft⋅lbf) 9. INSTALL REAR WHEEL AND LOWER VEHICLE 10. INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See page SA–6) 11. TORQUE NO.2 LOWER SUSPENSION ARM LOCK NUTS Torque: 56 N⋅m (570 kgf⋅cm. 41 ft⋅lbf) SA–95 SUSPENSION AND AXLE – REAR SUSPENSION STABILIZER BAR COMPONENTS STABILIZER BAR LINK INSPECTION INSPECT BALL JOINT FOR ROTATION CONDITION (a) Flip the ball joint stud back and forth 5 times as shown in the illustration, before installing the nut. (b) Using a torque gauge, turn the nut continuously one turn every 2–4 seconds and take the torque reading on the fifth turn. Turning torque: 0.05–1.0 N⋅m (0.5–10 kgf⋅cm, 0.4–8.7in.⋅lbf) If not within specification, replace the stabilizer bar link. SA–96 SUSPENSION AND AXLE – SERVICE SPECIFICATIONS SERVICE SPECIFICATIONS SERVICE DATA SEDAN/COUPE Cold tire inflation pressure Tire runout Wheel balance Front Rear Unbalance after adjustment Vehicle height Front wheel alignment Pressure Tire size Height Tire size Front Rear Inside wheel Outside wheel (reference) Toe – in (total) Tire size Wheel angle Camber Left–right error Caster Left–right error Rear wheel alignment Front axle Front suspension Steering axis inclination Toe–in (total) Camber Left – right error Axle bearing backlash Axle hub deviation Lower ball joint turning torque Stabilizer bar link turning torque Rear axle Axle bearing backlash Axle hub deviation Rear suspension Stabilizer bar link turning torque 1l04727 SA–97 SUSPENSION AND AXLE – SERVICE SPECIFICATIONS WAGON Cold tire inflation pressure Tire size Pressure Front Rear For all roads including full rated loads Optional inflation for reduced loads (1 or 4 passengers) Tire runout Wheel balance Unbalance after adjustment Vehicle height Front wheel alignment Height Tire size Front Toe –in (total) Tire size Wheel angle Camber Left–right error Caster Left–right error Rear wheel alignment Front axle Steering axis inclination Toe–in (total) Camber Left – right error Axle bearing backlash Axle hub deviation Front suspension Rear Lower ball joint turning torque Stabilizer bar link turning torque Rear axle Axle bearing backlash Rear suspension Axle hub deviation Stabilizer bar link turning torque Inside wheel Outside wheel (reference) SA–98 SUSPENSION AND AXLE TORQUE SPECIFICATIONS FRONT Part tightened Tie rod end lock nut Steering knuckle x Shock absorber Steering knuckle x Brake caliper Steering knuckle x Tie rod end Axle hub nut Ball joint x Lower arm Ball joint x Steering knuckle Steering knuckle x Disc brake dust cover Drive shaft x Side gear shaft (1 MZ–FE) Drive shaft center bearing lock bolt Suspension upper support x Body Suspension upper support x Piston rod Brake hose x Shock absorber ABS speed sensor wire x Shock absorber Lower arm set bolt Lower arm x Stabilizer bar link bracket Stabilizer bar bushing retainer Stabilizer bar link set nut Steering gear box set bolt Front exhaust pipe stay x Clamp (1 MZ–FE) Front exhaust pipe stay x Body (1 MZ–FE) REAR Part tightened Brake caliper x Rear axle carrier Axle bearing set bolt Bearing lock nut (w/o ABS) Shock absorber x Rear axle carrier Brake hose x Shock absorber ABS speed sensor set bolt ABS speed sensor wire x Shock absorber Suspension upper support x Body Suspension upper support x Piston rod Lower suspension arm x Suspension member Lower suspension arm X Rear axis carrier Strut rod x Body Strut rod x Rear axle carrier Suspension member x Body (17mm) Suspension member x Body (14mm) LSPV spring x Lower suspension arm Stabilizer bar bushing retainer Stabilizer bar link set nut – SERVICE SPECIFICATIONS SA–37 SUSPENSION AND AXLE – FRONT DRIVE SHAFT(5S–FE) LUBRICANT Drive shaft Item Capacity Toyota type Outboard joint grease Inboard joint grease 120–130 g (4.2–4.6 oz.) 232–242 g (8.2–8.5 oz.) GKN type Outboard joint grease Inboard joint grease 140–160 g (4.9–5.6 oz.) 185–215 g (6.5–7.6 oz.) SR–1 STEERING – STEERING SR–2 STEERING – GENERAL DESCRIPTION GENERAL DESCRIPTION • Care must be taken to replace parts properly because they could affect the performance of the steering system and result in a driving hazard. • The steering wheel pad has an airbag built in, so take all due precautions when handling it. For more details, see the SUPPLEMENTAL RESTRAINT SYSTEM (SRS) section. TROUBLESHOOTING Hard steering Poor return Excessive play Abnormal noise Front wheel bearing (Worn) Steering gear housing Sliding yoke (Worn) Steering column (Binding) SA–10 SA–63, 72 SR–24 Drive belt (Loose) Suspension arm ball joints (Worn) SR–24 Fluid level (Low) Steering system joints (Worn) SA–4 Trouble Front wheel alignment (Incorrect) Parts Name SA–4 See page Tires (improperly inflated) Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each parts in order. If necessary, replace these parts. SR–3 STEERING – ON–VEHICLE INSPECTION ON–VEHICLE INSPECTION CHECK THAT STEERING WHEEL FREEPLAY IS COR– RECT With the vehicle stopped and tires pointed straight ahead, rock the steering wheel gently back and forth with light finger pressure. Freeplay should not exceed the maximum. Maximum freeplay: 30 mm (1.18 In.) If incorrect, repair. SR–4 STEERING – STEERING COLUMN STEERING COLUMN PREPARATION SST (SPECIAL SERVICE TOOLS) 09213–31021 Crankshaft Pulley Puller Steering wheel 09612–22011 Tilt Handle Bearing Replacer 09309–37010 Transmission Bearing Replacer 09236–00101 Water Pump Overhaul Tool Set (09237–00010) Water Pump Bearing Remover & Replacer RECOMMENDED TOOLS 09042–00010 Torx Socket T30 09904–00010 Expander Set (09904–00050) No. 4 Claw EQUIPMENT Torque wrench Steering wheel pad SR–5 STEERING – STEERING COLUMN ASSEMBLY REMOVAL AND INSTALLATION Remove and install the parts, as shown. SR–6 STEERING – STEERING COLUMN MAIN POINTS OF REMOVAL AND INSTALLATION NOTICE: • If the SRS (Supplemental Restraint System) connec– tor is disconnected with the ignition switch at ON or ACC, diagnostic trouble codes will be recorded. • Never use SRS parts from another vehicle. When replacing parts, replace with new parts. 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is discon– nected from the battery. (See RS section) 2. REMOVE STEERING WHEEL PAD (a) Place the front wheels facing straight ahead. (b) Remove the No.2 and No.3 covers. (c) Using a torx wrench, loosen the screws. Produced by TMC: 3 screws Produced by TMM: 2 screws Torx wrench: T30 (Part No. 09042–00010 or locally manufactured tool) HINT: Loosen the torx screws until groove along the screw circumference catches on the screw case. (d) Pull the wheel pad out from the steering wheel and disconnect the SRS connector. NOTICE: When removing the wheel pad, take care not to pull the airbag wire harness. CAUTION: • When storing the wheel pad, keep the upper surface of the pad facing upward. • Never disassemble the wheel pad. SR–7 STEERING – STEERING COLUMN 3. REMOVE STEERING WHEEL (a) Disconnect the connector. (b) Remove the set nut. (c) Place matchmarks on the steering wheel and main shaft. (d) Using SST, remove the steering wheel. SST 09213–31021 4. INSTALL STEERING WHEEL (a) Align matchmarks on the steering wheel and main shaft, and install the wheel to the shaft. (b) Tighten the wheel set nut. Torque: 35 N–m (360 kgf–cm, 26 ft–lbf) (c) Connect the connector. 5. INSTALL STEERING WHEEL PAD (a) Connect the SRS connector. (b) Install the wheel pad after confirming that the circum– ference groove of the torx screws is caught on the screw case. (c) Using a torx wrench, tighten the screws. Produced by TMC: 3 screws Produced by TMM: 2 screws Torque: 8.8 N–m (90 kgf–cm, 78 in–lbf) NOTICE: • Make sure the wheel pad is installed to the specified torque. • If the wheel pad has been dropped, or there are cracks, dents or other defects in the case or connec– tor, replace the wheel pad with a new one. • When installing the wheel pad, take care that the wirings do not interfere with other parts and are not pinched between other parts. (d) Install the No.2 and No.3 covers. SR–8 STEERING – STEERING COLUMN 6. CHECK STEERING WHEEL CENTER POINT AFTER INSTALLING STEERING COLUMN 7. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY SR–9 STEERING – STEERING COLUMN STEERING COLUMN COMPONENTS SR–10 STEERING – STEERING COLUMN STEERING COLUMN DISASSEMBLY 1. REMOVE IGNITION KEY CYLINDER ILLUMINATION 2. REMOVE COLUMN UPPER BRACKET (a) Using a centering punch, mark the center of the 2 tapered–head bolts. (b) Using a 3–4 mm (0.12–0.16 in.) drill, drill into the 2 tapered–head bolts. (c) Using a screw extractor, remove the 2 tapered–head bolts. (d) Remove the column upper clamp bracket and the column tube. 3. ALIGN STEERING COLUMN Align the upper column tube and lower column tube. 4. REMOVE MAIN SHAFT (a) Using snap ring pliers, remove the snap ring. SR–11 STEERING – STEERING COLUMN (b) Using a screwdriver, loosen the staked parts of the upper column tube. (c) Using a plastic hammer, tap the main shaft until the main stopper contacts the collar. (d) Using SST, set the steering column on a press, as shown. SST 09236 –00101 (09237–00010) (e) Using a brass bar, press out the main shaft. NOTICE: To prevent damage to the main shaft avoid dropping it. 5. REMOVE MAIN SHAFT COLLAR AND BUSHING (a) Remove the collar from the main shaft. (b) Using snap ring pliers, remove the snap ring. SR–12 STEERING – STEERING COLUMN (c) Using a brassbar, tap the bushing off the main shaft. STEERING COLUMN INSPECTION AND REPLACEMENT 1. INSPECT STEERING LOCK OPERATION Check that the steering lock mechanism operates pro– perly. 2. IF NECESSARY, REPLACE KEY CYLINDER (a) Place the ignition key at the ACC position. (b) Push down the stop pin with a thin rod, and pull out the key cylinder. (c) Make sure the ignition key is at the ACC position. (d) Install a new key cylinder. 3. INSPECT UPPER BEARING Check the upper bearing condition by manually turn– ing the load bearing surface inside the column tube. If there is resistance to turning, or an uneven force is required to turn the bearing surface, replace the column tube. 4. INSPECT LOWER BEARING Check the lower bearing condition by manually turn– ing the load bearing surface outside the main shaft. If there is resistance to turning, or an uneven force is required to turn the bearing surface, replace the main shaft. SR–13 STEERING – STEERING COLUMN 5. (A/T) INSPECT KEY INTERLOCK SOLENOID (See AX section) 6. (A/T) IF NECESSARY, REPLACE KEY INTERLOCK SOLE– NOID (a) Remove the 2 screws and the solenoid. (b) Install a new solenoid with the 2 screws. STEERING COLUMN ASSEMBLY 1. COAT ALL RUBBING PARTS WITH MOLYBDENUM DISULPHIDE LITHIUM BASE GREASE 2. INSTALL MAIN SHAFT BUSHING AND COLLAR (a) Using SST, tap the bushing onto the main shaft. SST 09612–22011 (b) Using snap ring pliers, install the snap ring. (c) Install the collar on the bushing. (d) Insert the main shaft in the column tube. (e) Using SST, tap in the collar to the column tube. SST 09309–37010 SR–14 STEERING – STEERING COLUMN (f) Using SST, a 27 mm socket wrench (insert extension bar into the socket 19 mm) and a 19mm deep socket wrench, press in the main shaft. SST 09612 – 22011 (g) Using a pin punch and hammer, stake the upper column tube. (h) Using snap ring pliers, install the snap ring. 3. INSTALL UPPER BRACKET (a) Install the upper bracket with 2 new tapered–head bolts. (b) Tighten the 2 tapered–head bolts until the bolt head breaks off. 4. INSTALL IGNITION KEY CYLINDER ILLUMINATION SR–15 STEERING – POWER STEERING POWER STEERING DESCRIPTION POWER STEERING PRINCIPLES Power steering is a hydraulic device which utilizes engine power to reduce steering effort. Consequently, the engine is used to drive a pump to develop fluid pressure, and this pressure acts on a piston within the power cylinder so that the piston assists the rack effort. The amount of this assistance depends on the extent of pressure acting on the piston. Therefore, if more steering force is required, the pressure must be raised. The variation in the fluid pressure is accomplished by a control valve which is linked to the steering main shaft. NEUTRAL (STRAIGHT–AHEAD) POSITION Fluid from the pump is sent to the control valve. If the control valve is in the neutral position, all the fluid will flow through the control valve into the relief port and back to the pump. At this time, hardly any pressure is created and because the pressure on the cylinder piston is equal on both sides, the piston will not move in either direction. SR–16 STEERING – POWER STEERING WHEN TURNING When the steering main shaft is turned in either direction, the control valve also moves, closing one of the fluid passages. The other passage then opens wider, causing a change in fluid flow volume and, at the same time, a differential pressure is created between both sides of the piston. Consequently, the piston moves in the direction of the lower pressure so that the fluid in the cylinder is forced back to the pump through the control valve. SERVICE HINT Trouble with the power steering system usually involves hard steering resulting from lack of assistance. In such cases, before attempting to make repairs, you should determine whether the trouble lies with the pump or with the gear housing. To do this, use a pressure gauge to perform an on–vehicle inspection. (1MZ – FE Engine) This model is fitted with a hydraulic cooling fan system which is driven by the power steering flu,id. Accordingly, when inspecting the power steering system, you should also inspect the fluid passages of the hydraulic cooling fan system. ON–VEHICLE INSPECTION Power steering is a hydraulic device and problems are normally due to insufficient fluid pressure acting on the piston. This could be caused by either the pump not producing the specified fluid pressure or the control valve in the gear housing not functioning properly so that the proper fluid pressure can not be obtained. If the fault lies with the pump, the same symptoms will generally occur whether the steering wheel is turned fully to the right or left. On the other hand, if the fault lies with the control valve, there will generally be a difference between the amount of assistance when the steering wheel is turned to the left and right, causing harder steering. However, if the piston seal of the power cylinder is worn, there will be a loss of fluid pressure whether the steering wheel is turned to the right or left and the symptoms will be the same for both. Before performing an on–vehicle inspection, a check must first be made to confirm that the SR–17 STEERING – POWER STEERING power steering system is completely free of any air. If there is any air in the system, the volume of this air will change when the fluid pressure is raised, causing a fluctuation in the fluid pressure so that the power steering will not function properly. To determine if there is any air in the system, check if there is a change of fluid level in the reservoir tank when the steering wheel is turned fully to the right or left. If there is air in the system, it will be compressed to a smaller volume when the steering wheel is turned, causing a considerable drop in the fluid level. If the system is free of air, there will be very little change in the level even when the fluid pressure is raised. This is because the fluid, being a liquid, does not change volume when compressed. The small change in the fluid level is due to expansion of the hoses between the pump and gear housing when pressure rises. Also, air in the system sometimes causes abnormal noise in the pump or gear housing when the steering wheel is fully turned in either direction. This on–vehicle inspection must be performed every time after overhauling or repairing the pump or gear housing to ensure that the power steering system is working properly. VANE PUMP The main component parts of the vane pump, such as the cam ring, rotor, vanes and flow control valve are high precision parts and must be handled carefully. Also, because this pump produces a very high fluid pressure, 0–rings are used for sealing each part. When reassembling the pump, always use new 0 – rings. In the flow control valve, there is a relief valve which controls the maximum pressure of the pump. The amount of this maximum pressure is very important; if it is too low, there will be insufficient power steering assistance and if too high, it will have an adverse effect on the pressure hoses, oil seals, etc. If the maximum pressure is either too high or too low due to a faulty relief valve, do not disassemble or adjust the relief valve, but replace the flow control valve as an assembly. The clearance between the flow control valve and pump body installation hole is very important. After manufacture, the factory measures the size of the installation hole and outer circumference of the flow control valve, and punches a mark accordingly. Therefore, when replacing the flow control valve, be sure to do so with one having the same mark in order to ensure the proper clearance. SR–18 STEERING – POWER STEERING The functional parts of the pump which produce fluid pressure are the cam ring, rotor and vanes, and these should be checked for wear. If the clearance between each is not within standard when reassembling, any worn parts should be replaced. In this case, the replaced cam ring and rotor should be of the same length (have the same mark), and the vanes should be replaced with those having a length corresponding to that mark, otherwise the proper thrust clearance cannot be obtained. If there is too much thrust clearance, there will be insufficient fluid pressure at low speeds. If there is too little thrust clearance, it may result in seizure of the vanes. GEAR HOUSING If the gear housing is secured directly in a vise during overhaul, there is danger of deforming it, so always first secure it in the SST provided (rack and pinion steering rack housing stand) before placing it in the vise. The oil seals on both sides of the power cylinder are for the prevention of leakage of the high pressure fluid which acts on the piston. Always use new oil seals when reassembling and be very careful not to scratch or damage them. SR–19 STEERING – POWER STEERING Because of the high pressure, even the slightest scratch will cause fluid leakage, resulting in an inoperative power steering system. Also, be very careful not to scratch the sliding portion of the rack which makes contact with the oil seals. When removing the rack ends from the rack, it is very easy to cause a burr when holding the tip of the rack with a wrench. Therefore, before assembling the rack, first check the tip for burrs and remove any with an oil stone. Teflon rings are used for the piston and control valve. These teflon rings are highly durable against wear, but if it is necessary to replace them, be careful not so stretch the new ones. After installing a teflon ring into its groove, snug it down into the groove before assembly of the cylinder or housing to prevent possible damage. As with the rack and pinion type steering, preload is very important. If the preload is not correct, it could result in such trouble as steering wheel play or shimmy or lack of durability, so always make sure that it is correct. IDLE–UP DEVICE The pump produces the maximum fluid pressure when the steering wheel is turned fully to the right or left and, at this time, there is a maximum load on the pump which causes a decrease in engine idle rpm. To solve this problem, vehicles are equipped with an idle– up device which acts to raise the engine idle rpm whenever there is a heavy load on the pump. On EFI engines, when the piston of the air control valve is pushed by fluid pressure, the air valve opens and the volume of air by–passing the throttle valve is increased to regulate engine rpm. SR–20 STEERING – POWER STEERING PREPARATION SST (SPECIAL SERVICE TOOLS) 09238–47012 Water Pump Bearing Remover & Replacer PS pump bearing (3VZ–FE) 09608–12010 Front Hub & Drive Pinion Bearing Replacer Set Gear housing oil seal (09608–00080) Replacer 09612–00012 Rack & Pinion Steering Rack Housing Stand 09612–22011 Tilt Handle Bearing Replacer 09612–24014 Steering Gear Housing Overhaul Tool Set (09613–22011) Steering Rack Shaft Bushing Puller (09617–24020) Steering Pinion Bearing Adjusting Screw Lock Nut Wrench (09617–24030) Steering Rack End Wrench 09616–00010 Steering Worm Bearing Adjusting Socket 09616–30020 Steering Worm Bearing Adjusting Screw Wrench 09617–14010 Steering Rack End Wrench 09620–30010 Steering Gear Box Replacer Set Control valve oil seal SR–21 STEERING – POWER STEERING (09623–30010) Steering Worm Bearing & Oil Seal Replacer (09631 –00020) Handle 09628–62011 Ball Joint Puller 09630–24013 Steering Rack Oil Seal Tool Set (09620–24010) Valve Cup Oil Seal Remover (09620–24020) Valve Cup Oil Seal Replacer 09631–10021 Rack Stopper Wrench 09631 –10030 Oil Seal Remover 09631 –12020 Handle 09631–12071 Steering Rack Oil Seal Test Tool 09631–16010 Cylinder End Stopper Nut Wrench 09631–20081 Seal Ring Tool 09631–22020 Power Steering Hose Nut 14 x 17 mm Wrench Set 09631–33010 Steering Rack Cover ”I” Tie rod end SR–22 STEERING – POWER STEERING POWER STEERING PUMP (1 MZ–FE) POWER STEERING PUMP REMOVAL AND INSTALLATION Remove and install the parts, as shown. SR–23 STEERING – POWER STEERING 10. REMOVE SELF– LOCKING NUT Using SST to hold the control valve, remove the self– locking nut. SST 09616 – 00010 11. REMOVE CONTROL VALVE HOUSING (a) Remove the dust cover. (b) Place matchmarks on the valve housing and rack housing. (c) Remove the 2 bolts. (d) Pull out the valve with the valve housing. (e) Remove the gasket from the rack housing. 12. REMOVE CONTROL VALVE FROM HOUSING Tap out the control valve and oil seal. 13. REMOVE N0.2 BRACKET (a) Place matchmarks on the bracket and rack housing. (b) Using a screwdriver, pry a part the clasp of the No.2 bracket. (c) Remove the bushing and bracket from the rack hous– ing. (d) Remove the bushing from the bracket. SR–24 STEERING – POWER STEERING ON–VEHICLE INSPECTION DRIVE BELT TENSION CHECK Using a belt tension gauge, check the drive belt ten– sion. Belt tension gauge: Nippondenso BTG–20 (95506–00020) or Borroughs No.BT–33–73F Drive belt tension: 1 MZ–FE New belt 667–824 N (68–84 kgf, 150–185 lbf) Used belt 422–598 N (43–61 kgf, 95–135 lbf) 5S–FE New belt 441–667 N (45–68 kgf, 100–150 lbf) Used belt 275–441 N (28–45 kgf,60–100 lbf) HINT: • ”New belt’” refers to a belt which has been less than 5 minutes on a running engine. • ”Used belt’ refers to a belt which has been used on a running engine for 5 minutes or more. • After installing the drive belt, check that it fits properly in the ribbed grooves. FLUID LEVEL CHECK 1. KEEP VEHICLE LEVEL 2. BOOST FLUID TEMPERATURE With the engine idling at 1,000 rpm or less, turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80C (176F) 3. CHECK FOR FOAMING OR EMULSIFICATION HINT: Foaming and emulsification indicate either the existence of air in the system or that the fluid level is too low. 4. CHECK FLUID LEVEL IN OIL RESERVOIR Check the fluid level and add fluid if necessary. Fluid: ATF DEXRON
ll SR–25 STEERING – POWER STEERING HINT: Check that the fluid level is within the HOT LEVEL of the tank. If the fluid is cold, check that it is within the COLD LEVEL of the tank. IDLE–UP CHECK 1. WARM UP ENGINE 2. TURN AIR CONDITIONER SWITCH OFF 3. CHECK IDLE–UP (a) Fully turn the steering wheel. (b) Check that the engine rpm decreases when the air control valve hose is pinched. (c) Check that the engine rpm increases when the air control valve hose is released. POWER STEERING FLUID REPLACEMENT 1. JACK UP FRONT OF VEHICLE AND SUPPORT IT WITH STANDS SR–26 STEERING – POWER STEERING 2. REMOVE FLUID RETURN HOSE FROM OIL RESER– VOIR AND DRAIN FLUID INTO CONTAINER 3. TURN STEERING WHEEL FROM LOCK TO LOCK WHILE DRAINING FLUID 4. FILL OIL RESERVOIR WITH FRESH FLUID Fluid: ATF DEXRON
II SR–27 STEERING – POWER STEERING 5. START ENGINE AND RUN IT AT 1,000 RPM After 1 or 2 seconds, fluid will begin to discharge from the return hose. Stop the engine immediately at this time. NOTICE: Take care that some fluid remains left in the oil reservoir. 6. REPEAT STEPS 5 AND6 FOUR OR FIVE TIMES UNTIL THERE IS NO MORE AIR IN FLUID 7. CONNECT RETURN HOSE TO OIL RESERVOIR 8. BLEED POWER STEERING SYSTEM POWER STEERING SYSTEM BLEEDING 1. CHECK FLUID LEVEL IN OIL RESERVOIR Check the fluid level and add fluid if necessary. Fluid: ATF DEXRON
ll HINT: Check that the fluid level is within the HOT LEVEL of the dipstick of the oil reservoir. If the fluid is cold, check that it is within the COLD LEVEL of the dipstick. 2. START ENGINE AND TURN STEERING WHEEL FROM LOCK TO LOCK 3 OR 4 TIMES With the engine speed below 1,000 rpm, turn the steering wheel to left or right full lock and keep it there for 2–3 seconds, then turn the wheel to the opposite full lock and keep it there for 2–3 seconds. 3. CHECK THAT FLUID IN OIL RESERVOIR IS NOT FOAMY OR CLOUDY AND DOES NOT RISE OVER MAXIMUM WHEN ENGINE IS STOPPED Measure the fluid level with the engine running. Stop the engine and measure the fluid level. Maximum rise: 5 mm (0.20 in.) If a problem is found, repeat steps 5 to6 on page SR–27. Repair the PS if the problem persists. SR–28 STEERING – POWER STEERING OIL PRESSURE CHECK 1. CONNECT OIL PRESSURE GAUGE 1 MZ–FE (a) Using SST, disconnect the pressure line joint. SST 09631 –22020 (b) Connect the gauge side of the pressure gauge to the PS pump side and the valve side to the gear housing side. 2. BLEED POWER STEERING SYSTEM (See page SR–27) 5S–FE (a) Disconnect the pressure tube from the PS pump. (b) Connect the gauge side of the pressure gauge to the PS pump and the valve side to the pressure line. 3. BLEED POWER STEERING SYSTEM (See page SR–27) 4. START ENGINE AND RUN IT AT IDLE 5. BOOST FLUID TEMPERATURE With the engine idling at 1,000 rpm or less, turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80 C (176 F) SR–29 STEERING – POWER STEERING 6. CHECK FLUID PRESSURE READING WITH VALVE CLOSED Close the oil pressure gauge valve and observe the reading on the gauge. Minimum pressure: 1 MZ – FE 9,120 kPa (93 kgf/cm2, 1,323 psi) 5S–FE 8,336 kPa (85 kgf/cm2, 1,209 psi) NOTICE: • Do not keep the valve closed for more than 10 seconds. • Do not let the fluid temperature become too high. If pressure is low, repair or replace the PS pump. 7. OPEN VALVE FULLY 8. CHECK AND RECORD PRESSURE READING AT 1,000 RPM 9. CHECK AND RECORD PRESSURE READING AT 3,000 RPM Check that there is 490 kPa (5 kgf/cm2, 71 psi) or less difference in pressure between the 1,000 rpm and 3,000 rpm checks. If the difference is excessive, repair or replace the flow control valve of the PS pump. SR–30 STEERING – POWER STEERING 10. CHECK PRESSURE READING WITH STEERING WHEEL TURNED TO FULL LOCK Be sure the pressure gauge valve is fully opened and the engine idling. Minimum pressure: 1 MZ–FE 9,120 kPa (93 kgf/cm2, 1,323 psi) 5S–FE 8,336 kPa (85 kgf/cm2, 1,209 psi) NOTICE: • Do not maintain lock position for more than 10 seconds. • Do not let the fluid temperature become too high. If pressure is low, the gear housing has an internal leak and must be repaired or replaced. 11. MEASURE STEERING EFFORT (a) Center the steering wheel and run the engine at idle. (b) Using a spring scale, measure the steering effort in both directions. Maximum steering effort: 39 N (4 kgf, 8.8 lbf) If steering effort is excessive, repair the PS unit. HINT: Be sure to consider the tire type, pressure and contact surface before making your diagnosis. SR–31 STEERING – POWER STEERING POWER STEERING PUMP (5S–FE) POWER STEERING PUMP REMOVAL AND INSTALLATION Remove and install the parts, as shown. MAIN POINTS OF REMOVAL AND INSTALLATION 1. ADJUST DRIVE BELT TENSION AFTER INSTALL– ING PS PUMP 2. BLEED POWER STEERING SYSTEM SR–32 STEERING – POWER STEERING COMPONENTS SR–33 STEERING – POWER STEERING ~1 –01 POWER STEERING PUMP DISASSEMBLY 1. MOUNT POWER STEERING PUMP IN VISE NOTICE: Do not tighten the vise too tight. 2. REMOVE PS PUMP PULLEY (a) Using SST, remove the pulley set nut. SST 09960–10010 (09963–01000) (b) Remove the pump pulley from the shaft. 3. REMOVE SUCTION PORT UNION (a) Remove the bolt and union. (b) Remove the O–ring from the union. 4: REMOVE AIR CONTROL VALVE (a) Remove the air control valve. (b) Remove the gasket. 5. REMOVE FLOW CONTROL VALVE (a) Remove the pressure port union. (b) Remove the 0–ring from the union. (c) Remove the flow control valve and spring. 6. REMOVE PUMP BRACKET (a) Remove the 3 bolt. (b) Remove the pump bracket from the pump assy. SR–34 STEERING – POWER STEERING 7. REMOVE REAR HOUSING (a) Remove the 4 bolt. (b) Remove the rear housing. (c) Remove the wave washer. (d) Remove the side plate. 8. REMOVE PUMP SHAFT, CAM RING AND VANE PLATES (a) Using snap ring pliers, remove the snap ring. (b) Remove the cam ring and 10 vane plates from the front housing. 9. REMOVE ROTER (a) Remove the roter from the pump shaft. SR–35 STEERING – POWER STEERING (b) Remove the 2 straight pins from the front housing. (c) Remove the gasket. (d) Remove the pump shaft. POWER STEERING PUMP INSPECTION AND REPLACEMENT 1. MEASURE OIL CLEARANCE OF SHAFT AND BUSH– ING Using a micrometer and calipers, measure the oil cle– arance. Standard clearance: 0.03–0.05 mm (0.0012–0.0020 in.) Maximum clearance: 0.07 mm (0.0028 in.) If more than maximum, replace the entire power steer– ing pump. 2. INSPECT ROTOR AND VANE PLATES (a) Using a micrometer, measure the height, thickness and length of the vane plates. Minimum height: 8.6 mm (0.339 in.) Minimum thickness: 1.4 mm (0.055 in.) Minimum length: 14.99 mm (0.5902 in.) SR–36 STEERING – POWER STEERING (b) Using a feeler gauge, measure the clearance between the rotor groove and vane plate. Maximum clearance: 0.03 mm (0.0012 in.) If more than maximum, replace the vane plate and/or rotor with one having the same mark stamped on the cam ring. Inscribed mark: 1, 2, 3, 4 or None HINT: There are 5 vane lengths with the following rotor and cam ring marks: Rotor and cam ring mark Vane length mm (in.) None 14.999 –15.001 (0.59051 –0.59059) 14.997–14.999 (0.59043–0.59051) 14.995–14.997 (0.59035–0.59043) 14.993–14.995 (0.59027–0.59035) 14.911 –14.993 (0.59020–0.59027) 3. INSPECT FLOW CONTROL VALVE (a) Coat the valve with power steering fluid and check that it falls smoothly into the valve hole by its own weight. (b) Check the flow control valve for leakage. Close one of the holes and apply compressed air [392 –490 kPa (4–5 kgf/cm2, 57–71 psi)] into the oppo– site side, and confirm that air does not come out from the end holes. If necessary, replace the valve with one having the same letter as inscribed on the front housing. Inscribed mark: A, B, C, D, E or F SR–37 STEERING – POWER STEERING 4. INSPECT FLOW CONTROL SPRING Using a scale, measure the free length of the spring. Spring length: 36–38 mm (1.42–1.49 in.) If not within specification, replace the spring. 5. IF NECESSARY, REPLACE OIL SEAL (a) Using a screwdriver, pry out the oil seal. (b) Coat a new oil seal lip with power steering fluid. NOTICE: Make sure you install the oil seal facing the correct direction. (c) Using a socket wrench (24mm) and hummer, drive in a new oil seal. POWER STEERING PUMP ASSEMBLY 1. COAT ALL SLIDING SURFACES WITH POWER STE– ERING FLUID BEFORE ASSEMBLY 2. INSTALL PUMP SHAFT 3. INSTALL GASKET 4. INSTALL STRAIGHT PINS Using a plastic hammer, drive the 2 straight pin to the front plate. SR–38 STEERING – POWER STEERING 5. INSTALL CAM RING, ROTOR AND VANE PLATES (a) Install the roter to the shaft with the inscribed mark facing outward. (b) Align the holes of the cam ring and straight pins, and install the cam ring with the inscribed mark facing outward. (c) Using snap ring pliers, install the snap ring. (d) Coat the vane plates with power steering fluid. (e) Install the 10 vane plates with the round end facing outward. 6. INSTALL SIDE PLATE AND WAVE WASHER (a) Align the holes of the side plate with the pins, and install the plate. (b) Install the wave washer. SR–39 STEERING – POWER STEERING 7. INSTALL REAR HOUSING Install and torque the 4 bolts. Torque: 43 N–m (440 kgf–cm, 22 ft–lbf) 8. MEASURE PUMP SHAFT PRELOAD (a) Check that the shaft rotates smoothly without abnor– mal noise. (b) Temporarily install the pulley nut and check the rotat– ing torque. Rotating torque: 0.3 N–m (2.8 kgf–cm, 2.4 in.–lbf) or less 9. INSTALL PUMP BRACKET Install the pump bracket with the 3 bolts. Torque: 17 N–m (170 kgf–cm, 12 ft–lbf) 10. INSTALL FLOW CONTROL VALVE (a) Install the spring and flow control valve into the hous– ing. (b) Coat a new O–ring with power steering fluid, and install it to the pressure port union. (c) Install and torque the pressure port union. Torque: 83 N–m (850 kgf–cm, 62 ft–lbf) 11. INSTALL AIR CONTROL VALVE (a) Install a new gasket. (b) Install the air control valve. Torque: 69 N–m (700 kgf–cm. 51 ft–lbf) SR–40 STEERING – POWER STEERING 12. INSTALL SUCTION PORT UNION (a) Coat a new O–ring with power steering fluid, and install it to the suction port union. (b) Install the suction port union. (c) Install and torque the bolt. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) 13. INSTALL PS PUMP PULLEY (a) Install the pump pulley to the shaft. (b) Using SST, install and torque the pulley set nut. SST 09960–10010 (09963–01000) Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) SR–41 STEERING – POWER STEERING POWER STEERING PUMP (1MZ–FE) POWER STEERING PUMP REMOVAL AND INSTALLATION Remove and install the parts, as shown. SR–42 STEERING – POWER STEERING MAIN POINTS OF REMOVAL AND INSTALLATION 1. REMOVE PRESSURE TUBES Using SST, remove the pressure tubes. SST 09631–22020 2. ADJUST DRIVE BELT TENSION AFTER INSTALL– ING PS PUMP 3. BLEED POWER STEERING SYSTEM SR–43 STEERING – POWER STEERING COMPONENTS SR–44 STEERING – POWER STEERING POWER STEERING PUMP DISASSEMBLY 1. MOUNT POWER STEERING PUMP IN VISE NOTICE: Do not tighten the vise to tight. 2. REMOVE PS PUMP PULLEY (a) Using SST, remove the pulley set nut. SST 09960–10010 (09963–01000) (b) Remove the pump pulley from the shaft. 3. REMOVE CONTROL VALVE (a) Using SST, remove the control valve. SST 09612–24014 (09617–24030) (b) Remove the O–ring from the control valve. (c) Remove the O–ring from the rear housing. 4. REMOVE SUCTION PORT UNIONS (a) Remove the 3 bolts and 2 suction port unions. (b) Remove the O–ring from each suction port union. 5. REMOVE FLOW CONTROL VALVE For PS: (a) Remove the pressure port union. (b) Remove the 0–ring from the pressure port union. SR–45 STEERING – POWER STEERING (c) Using a magnetic finger, remove the flow control valve and spring. NOTICE: Be careful not to confute the flow control valve of the PS with that of the hydraulic cooling fan system. 6. REMOVE FLOW CONTROL VALVE For Hydraulic Cooling Fan System: (a) Remove the pressure port union. (b) Remove the O–ring from the pressure port union. (c) Using a magnetic finger, remove the flow control valve and spring. NOTICE: Be careful not to confuse the flow control valve of the hydraulic cooling fan system with that of the PS. 7. REMOVE REAR HOUSING Using a hexagon wrench (8 mm), remove the 4 bolts, rear housing and gasket. 8. REMOVE CAM RING, ROTOR AND VANE PLATE For Hydraulic Cooling Fan System: Remove the cam ring, rotor and 10 vane plates. NOTICE: Be careful not to confuse the cam ring, rotor and vane plates of the hydraulic cooling fan system with those of the PS. SR–46 STEERING – POWER STEERING 9. REMOVE FRONT SIDE PLATE AND 2 REAR SIDE PLATES (a) Remove the front side plate and 2 rear side plates. (b) Remove the 2 0–rings from the rear side plate. 10. REMOVE CAM RING, ROTOR AND VANE PLATES For PS: Remove the cam ring, rotor and 10 vane plates. NOTICE: Be careful not to confuse the cam ring, rotor and vane plates of the PS with those of the hydraulic cooling fan system. 11. REMOVE STRAIGHT PINS Put each straight pin in the vise and rotate the hous– ing to pull the straight pin out from the housing. 12. REMOVE PUMP SHAFT (a) Using snap ring pliers, remove the snap ring. (b) Using a plastic hammer, tap out the pump shaft. SR–47 STEERING – POWER STEERING 13. REMOVE REAR SIDE PLATE AND WAVE WASHER FROM REAR HOUSING (a) Install a suitable bolt and plate washer to the rear plate. (b) Using SST, remove the rear plate. SST 09910 – 00015 (09911– 00011, 09912 – 00010) (c) Remove the 2 0– rings from the rear side plate. (d) Remove the wave washer. POWER STEERING PUMP INSPECTION AND REPLACEMENT NOTICE: Be careful not to confuse the parts of the PS with those of the hydraulic cooling fan system. 1. MEASURE OIL CLEARANCE OF SHAFT AND BUSH– ING Using a micrometer and calipers, measure the oil cle– arance. Standard clearance: 0.03–0.05 mm (0.0012–0.0020 in.) Maximum clearance: 0.07 mm (0.0028 in.) If more than maximum, replace the entire power steer– ing pump. 2. INSPECT ROTOR AND VANE PLATES (a) Using a micrometer, measure the height, thickness and length of the vane plates. For PS Minimum height: 8.6 mm (0.339 in.) Minimum thickness: 1.4 mm (0.055 in.) Minimum length: 14.99 mm (0.5902 in.) SR–48 STEERING – POWER STEERING For Hydraulic Cooling Fan System Minimum height: 8.1 mm (0.319 in.) Minimum thickness: 1.8 mm (0.071 in.) Minimum length: 14.98 mm (0.5898 in.) (b) Using a feeler gauge, measure the clearance between the rotor groove and vane plate. Maximum clearance: 0.035 mm (0.0014 in.) If more than maximum, replace the vane plate and/or rotor. HINT: There are 5 lengths with the following rotor and cam ring marks. Power Steering Vane Lengths Cam ring mark Rotor mark Vane length mm (in.) Hydraulic Cooling Fan System Vane Lengths Cam ring mark Rotor mark Vane length mm (in.) SR–49 STEERING – POWER STEERING 3. INSPECT FLOW CONTROL VALVE (a) Coat the valve with power steering fluid and check that it falls smoothly into the valve hole by its own weight. (b) Check the flow control valve for leakage. Close one of the holes and apply compressed air [392 –490 kPa (4–5 kgf/cm2, 57–71 psi)] into the oppo– site side, and confirm that air does not come out from the end holes. If necessary, replace the valve with one having the same letter as inscribed on the front housing. Inscribed mark: A, B, C, D, E or F 4. INSPECT FLOW CONTROL SPRING Using a scale, measure the free length of the spring. Spring length: 37–39 mm (1.46–1.54 in.) 5. IF NECESSARY, REPLACE OIL SEAL (a) Using SST and a hammer, drive out the oil seal. SST 09631–10030 SR–50 STEERING – POWER STEERING (b) Coat a new oil seal lip with power steering fluid. NOTICE: Make sure you install the oil seal facing the correct direction. (c) Using a socket wrench (24 mm) and hammer, drive in a new oil seal. 6. IF NECESSARY, REPLACE BALL BEARING (a) Using a press, remove the ball bearing from the pump shaft. (b) Using snap ring pliers, remove the snap ring from the pump shaft. (c) Using snap ring pliers, install the snap ring to the pump shaft. (d) Using a press and deep socket wrench (17 mm), install a new ball bearing to the pump shaft. SR–51 STEERING – POWER STEERING POWER STEERING PUMP ASSEMBLY 1. COAT ALL SLIDING SURFACES WITH POWER STE– ERING FLUID BEFORE ASSEMBLY 2. INSTALL PUMP SHAFT (a) Using SST and a press, install the pump shaft with the ball bearing. SST 09238–47012 (b) Using snap ring pliers, install the snap ring. 3. INSTALL STRAIGHT PINS Using a plastic hammer, tap in the 2 straight pins. 4. INSTALL CAM RING, ROTOR AND VANE PLATES For PS: (a) Align the holes of the cam ring and straight pins, and install the cam ring with the inscribed mark facing outward. (b) Install the rotor to the shaft with the inscribed mark facing outward. (c) Coat the vane plates with power steering fluid. (d) Install the 10 vane plates with the round end facing outward. 5. INSTALL FRONT SIDE PLATE AND 2 REAR SIDE PLATES (a) Install 2 new 0–rings to the rear side plate. (b) Align the holes of the plates and straight pins, and install the plates. SR–52 STEERING – POWER STEERING 6. INSTALL CAM RING, ROTOR AND VANE PLATES For Hydraulic Cooling Fan System: (a) Align the holes of the cam ring and straight pins, and install the cam ring with the inscribed mark facing outward. (b) Install the rotor to the shaft with the inscribed mark facing outward. (c) Coat the vane plates with power steering fluid. (d) Install the 10 vane plates with the round end facing outward. 7. INSTALL REAR SIDE PLATE AND WAVE WASHER (a) Install 2 new 0–rings to the rear side plate. (b) Align the holes of the side plate with the pins, and install the plate. (c) Install the wave washer. 8. INSTALL REAR HOUSING (a) Install a new gasket and the rear housing. HINT: Be careful when aligning the gasket. (b) Using a hexagon wrench (8 mm), install and torque the 4 bolts. Torque: 46 N–m (470 kgf–cm, 34 ft–lbf) 9. MEASURE PUMP SHAFT PRELOAD (a) Check that the shaft rotates smoothly with out abnor– mal noise. (b) Temporarily install the pulley nut and check the rotat– ing torque. Rotating torque: 0.3 N–m (2.8 kgf–cm, 2.4 in.–lbf) or less 10. INSTALL FLOW CONTROL VALVE For Hydraulic Cooling Fan System: (a) Install the spring and flow control valve into the hous– ing. SR–53 STEERING – POWER STEERING (b) Coat a new O–ring with power steering fluid, and install it to the pressure port union. (c) Install and torque the pressure port union. Torque: 69 N–m (700 kgf–cm, 61 ft–lbf) 11. INSTALL FLOW CONTROL VALVE For PS: (a) Install the spring and flow control valve into the hous– ing. (b) Coat a new O–ring with power steering fluid, and install it to the pressure port union. (c) Install and torque the pressure port union. Torque: 69 N–m (700 kgf–cm, 51 ft–Ibf) 12. INSTALL SUCTION PORT UNIONS (a) Coat 2 new 0–rings with power steering fluid, and install them to each suction port union. (b) Install the suction port union with the 3 bolts. Torque: 13 N–m (130 kgf–cm, 9 ft–lbf) 13. INSTALL CONTROL VALVE (a) Coat a new O–ring with power steering fluid, and install it to the rear housing. (b) Install a new O–ring to the control valve. SR–54 STEERING – POWER STEERING (c) Using SST, install and torque the control valve. SST 09612–24014 (09617–24030) Torque: 59 N–m (600 kgf–cm, 43 ft–lbf) HINT: Use a torque wrench with a fulcrum length of 340 mm (13.39 in.). 14. INSTALL PS PUMP PULLEY (a) Install the pump pulley to the shaft. (b) Using SST, install and torque the pulley set nut. SST 09960–10010 (09963–01000) Torque: 43 N–m (440 kgf–cm, 32 ft–lbf) SR–55 STEERING – POWER STEERING GEAR HOUSING STEERING GEAR HOUSING REMOVAL AND INSTALLATION Remove and install the parts, as shown. MAIN POINTS OF REMOVAL AND INSTALLATION NOTICE: When disconnecting the sliding yoke during re– moval of the gear housing, remove the steering wheel and perform centering of the spiral cable. (See page RS–20) If the operation is performed without removing the steer– ing wheel, use the procedure below to make sure the steering wheel is firmly fixed in position and cannot turn. SR–56 STEERING – POWER STEERING 1. DISCONNECT SLIDING YOKE (a) Position the front wheels facing straight ahead. (b) Using the seat belt of the driver’s seat, fix the steering wheel so that it does not turn. (c) Place matchmarks on the sliding yoke and control valve shaft. (d) Loosen the bolt on the upper side of the sliding yoke, remove the bolt on the lower side and disconnect the sliding yoke. 2. DISCONNECT TIE ROD ENDS (a) Remove the cotter pins and nuts. (b) Using SST, disconnect the tie rod end from the knuck– le arm. SST 09628–62011 3. DISCONNECT PRESSURE AND RETURN TUBES Using SST, disconnect and connect the pressure and return tubes. SST 09631 –22020 Torque: 25 N–m (250 kgf–cm, 18 ft.–lbf) 4. REMOVE STABILIZER BAR SET BOLTS Remove the 4 stabilizer bar set bolts. SR–57 STEERING – POWER STEERING 5. REMOVE GEAR HOUSING (a) Remove the 2 set bolts. (b) Slide the gear housing to the RH side. NOTICE: Do not damage the turn pressure tube. 6. CONNECT SLIDING YOKE (a) Set the gear housing so that it matches the dimen– sions shown below, with the gear housing at the center point. (b) Align matchmarks on the sliding yoke and control valve shaft and connect them. 7. CENTER SPIRAL CABLE If the steering wheel has been removed, or the steer– ing wheel may have moved during the operation, always perform centering of the spiral cablle. (See page RS–20) 8. CHECK STEERING WHEEL CENTER POINT 9. CHECK TOE–IN SR–58 STEERING – POWER STEERING COMPONENTS SR–59 STEERING – POWER STEERING STEERING GEAR HOUSING DISASSEMBLY 1. CLAMP GEAR HOUSING IN VISE Using SST, secure the steering gear in a vise. SST 09612–00012 2. REMOVE LEFT AND RIGHT TURN PRESSURE TUBES (a) Using SST, remove the turn pressure tubes. SST 09630–00020 (b) Remove the 0–rings from the turn pressure tubes. 3. REMOVE TIE ROD ENDS (a) Loosen the lock nut and place matchmarks on the tie rod end and rack end. (b) Remove the tie rod ends and lock nuts. 4. REMOVE RACK BOOTS (a) Using a screwdriver, remove the clips and clamps. (b) Remove the rack boots. NOTICE: Be careful not to damage the rack boots and rack housing. 5. REMOVE RACK ENDS AND CLAW WASHERS (a) Unstake the claw washers. NOTICE: Avoid any impact to the rack. SR–60 STEERING – POWER STEERING (b) Using SST, remove the rack ends. SST 09617–14010 (e) Mark the left and right rack ends accordingly. (d) Remove the claw washers. 6. REMOVE RACK GUIDE SPRING CAP LOCK NUT Using SST, remove the rack guide spring cap lock nut. SST 09612 – 24014 (09617 – 24020) 7. REMOVE RACK GUIDE SPRING CAP Using SST, remove the rack guide spring cap. SST 09631 –10021 8. REMOVE RACK GUIDE SPRING, RACK GUIDE AND SEAT 9. REMOVE RACK HOUSING GAP SR–61 STEERING – POWER STEERING 10. REMOVE SELF– LOCKING NUT Using SST to hold the control valve, remove the self– locking nut. SST 09616 – 00010 11. REMOVE CONTROL VALVE HOUSING (a) Remove the dust cover. (b) Place matchmarks on the valve housing and rack housing. (c) Remove the 2 bolts. (d) Pull out the valve with the valve housing. (e) Remove the gasket from the rack housing. 12. REMOVE CONTROL VALVE FROM HOUSING Tap out the control valve and oil seal. 13. REMOVE N0.2 BRACKET (a) Place matchmarks on the bracket and rack housing. (b) Using a screwdriver, pry a part the clasp of the No.2 bracket. (c) Remove the bushing and bracket from the rack hous– ing. (d) Remove the bushing from the bracket. SR–62 STEERING – POWER STEERING 14. REMOVE CYLINDER END STOPPER (a) Using SST, turn the cylinder end stopper clockwise until the wire end comes out. SST 09631 –16010 (b) Using SST, turn the cylinder end stopper counter– clockwise, and remove the wire. SST 09631 –16010 15. REMOVE RACK BUSHING AND RACK (a) Using a brass bar, tap out the rack with the rack busing. (b) Remove the 0–ring from the bushing. 16. REMOVE CYLINDER SIDE OIL SEAL AND SPACER Using SST and a brass bar, drive out the oil seal and spacer. SST 09620–30010 (09623–30010) W” –01 STEERING GEAR HOUSING INSPECTION AND REPLACEMENT 1. INSPECT RACK (a) Using a dial indicator, check the rack for runout and for tooth wear or damage. Maximum runout: 0.3 mm (0.012 in.) (b) Check the back surface for wear or damage. If faulty, replace it. 2. IF NECESSARY, REPLACE CONTROL VALVE HOUS– ING OIL SEAL AND UPPER BEARING (a) Using SST, press out the oil seal and upper bearing. SST 09620–30010 (09631 –00020) 09630–24013 (09620–24020) SR–63 STEERING – POWER STEERING (b) Coat a new oil seal with power steering fluid. (c) Using SST, press in a new oil seal, as shown. SST 09620–30010 (09631–00020) 09630–24013 (09620–24020) (d) Using SST, press in a new upper bearing, as shown. SST 09620–30010 (09631–00020) 09630–24013 (09620–24020) NOTICE: Press in the bearing so that the inscribed mark on the bearing can be seen. 3. IF NECESSARY, REPLACE CONTROL VALVE LOWER BEARING AND CENTER BEARING (a) Using a brass bar, drive out the lower bearing. (b) Using SST, remove the center bearing. SST 09612 – 24014 (09613 – 22011) (c) Coat a new center bearing with grease. (d) Using SST, press in a new center bearing, as shown. SST 09630–24013 (09620–24020), 09631–12020 SR–64 STEERING – POWER STEERING (e) Using SST, press in a new lower bearing. SST 09630–24013 (09620–24020), 09631 –12020 4. IF NECESSARY, REPLACE RACK BUSHING OIL SEAL (a) Using SST, remove the oil seal. SST 09612 – 24014 (09613 – 22011) (b) Coat a new oil seal with power steering fluid. (c) Using SST, press in the oil seal. SST 09631–32010 5. IF NECESSARY, REPLACE STEERING RACK TEFLON RING AND O–RING (a) Using a screwdriver, remove the teflon ring and 0– ring. NOTICE: Be careful not to damage the groove for the teflon ring. (b) Coat a new O–ring with power steering fluid and install it. (c) Expand a new teflon ring with your fingers. NOTICE: Be careful not to over–expand the teflon ring. SR–65 STEERING – POWER STEERING (d) Install the teflon ring to the rack. (e) Install the expanded teflon ring to the steering rack and snug it down with your fingers. 6. IF NECESSARY, REPLACE CONTROL VALVE TEFLON RINGS (a) Using a screwdriver, remove the 4 teflon rings. NOTICE: Be careful not to damage the grooves for the teflon ring. (b) Expand 4 new teflon rings with your fingers. NOTICE: Be careful not to over–expand the teflon ring. (c) Install the 4 teflon rings to the control valve. (d) Coat the 4 teflon rings with power steering fluid and snug them down with your fingers. (e) Carefully slide the tapered end of the SST over the teflon rings to seat the rings. SST 09631– 20081 NOTICE: Be careful not to damage the teflon rings. SR–66 STEERING – POWER STEERING 7. IF NECESSARY, REPLACE HYDRAULIC REACTION CHAMBER TEFLON RINGS AND O–RINGS (a) Remove the teflon rings and 0–rings. NOTICE: Be careful not to damage the control valve. (b) Install new 0–rings to the control valve. (c) Install the expanded new teflon rings to the control valve. (d) Carefully position the teflon rings into the control valve grooves. NOTICE: Be careful not over–expand the teflon rings. (e) Coat the teflon rings with power steering fluid, and snug them down with your fingers. NOTICE: Be careful not to damage the teflon rings. STEERNG GEAR HOUSING ASSEMBLY” 1. INSTALL CYLINDER HOUSING OIL SEAL AND SPACER (a) Coat a new oil seal lip with power steering fluid. (b) Tape the showing part of SST before use. (c) Install the oil seal to SST, and press in it. SST 09608–12010 (09608–00080), 09631 –12020 2. INSTALL RACK (a) Install SST to the rack. HINT: If necessary, scrape the burrs off the rack teeth end and burnish. SST 09631 –33010 (b) Coat SST with power steering fluid. (e) Insert the rack into the cylinder. (d) Remove SST. SR–67 STEERING – POWER STEERING 3. INSTALL RACK BUSHING AND CYLINDER END STOPPER (a) To prevent oil seal lip damage, wind vinyl tape on the steering rack end, and apply power steering fluid. (b) Coat a new O–ring with power steering fluid and install it to the bushing. (c) Push in the rack bushing and cylinder end stopper until the wire installation hole appears. 4. INSTALL WIRE (a) Insert a new wire end into the hole. (b) Using SST, turn the cylinder end stopper clockwise until the wire end disappears. SST 09631–16010 NOTICE: Take care to avoid tightening the rack more than needed. 5. AIR TIGHTNESS TEST (a) Install SST to the unions of the cylinder housing. SST 09631–12071 (b) Apply 53.3 kPa (400 mmHg, 15.75 in.Hg) of vacuum for about 30 seconds. (c) Check that there is no change in the vacuum. If there is change in the vacuum, check the installation of the rack housing oil seal. 6. INSTALL NO.2 BRACKET (a) Coat the grommets inner edge with the grease. (b) Install the bushing to the bracket. (c) Install the bushing and bracket to the rack housing. HINT: Align the matchmarks on the bracket and rack housing. SR–68 STEERING – POWER STEERING (d) Place the No.2 bracket in a vise and tighten the vise to fasten the clasp. NOTICE: Take care not to drop the from the No.2 bracket. 7. INSTALL CONTROL VALVE (a) Wind vinyl tape on the control valve. (b) Coat the teflon rings with power steering fluid. (c) Push the control valve into the housing. NOTICE: Be careful not to damage the teflon rings and oil seal. (d) Coat a new oil seal with power steering fluid. (e) Using SST, press in the new oil seal. SST 09612–22011 8. INSTALL CONTROL VALVE HOUSING (a) Place a new gasket on the rack housing. (b) Align the matchmarks on the valve housing and rack housing. (c) Torque the 2 bolts. Torque: 18 N–m (185 kgf–cm, 13 ft–lbf) (d) Install the dust cover. 9. INSTALL SELF– LOCKING NUT Using SST to hold the control valve, install a new self –locking nut. SST 09616 – 00010 Torque: 25 N–m (250 kgf–cm, 18 ft–lbf) NOTICE: Take care to avoid tightening the rack more than needed. SR–69 STEERING – POWER STEERING 10. INSTALL RACK HOUSING CAP (a) Apply sealant to 2 or 3 threads of the housing cap. Sealant: Part No.08833 – 00080, THREE BOND 1344, LOC– TITE 242 or equivalent (b) Install the rack housing cap. Torque: 59 N–m (600 kgf–cm, 43 ft–Ibf) (c) Using a center punch, stake the housing at 2 places. 11. INSTALL RACK GUIDE SEAT, RACK GUIDE AND SPRING (a) Coat the fitting surfaces between the rack guide seat and the rack guide with grease. (b) Install the rack guide seat, rack guide and spring. 12. ADJUST TOTAL PRELOAD (a) Apply sealant to 2 or 3 threads of the spring cap. Sealant: Part No.08833–00080, THREE BOND 1344, LOC– TITE 242 or equivalent (b) Using SST, install and torque the spring cap. SST 09631 –10021 Torque: 25 N–m (250 kgf–cm, 18 ft–Ibf) (c) Using SST, return the rack guide spring cap 12
. SST 09631–10021 (d) Turn the control valve shaft right and left 1 or 2 times. (e) Loosen the spring cap until the rack guide compres– sion spring is not functioning. SR–70 STEERING – POWER STEERING (f) Using SST and torque meter, tighten the rack guide spring cap until the preload is within specification. SST 09616–00010, 09631 –10021 Preload (turning): 0.8–1.4 N–m (8–14 kgf–cm, 6.9–12.2 in.–Ibf) 13. INSTALL RACK GUIDE SPRING CAP LOCK NUT (a) Apply sealant to 2 or 3 threads of the lock nut. Sealant: Part No.08833–00080, THREE BOND 1344, LOC– TITE 242 or equivalent (b) Using SST, install and torque the lock nut. SST 09612–24014 (09617–24020), 09631–10021 Torque: 55 N–m (560 kgf–cm. 41 ft–lbf) HINT: Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). (c) Recheck the total preload. 14. INSTALL RACK ENDS (a) Install a new claw washer. (b) Using SST, install the rack ends. SST 09617 –14010 Torque: 72 N–m (730 kgf–cm, 53 ft–lbf) HINT: Use a torque wrench with a fulcrum length of 340 mm (13.39 in.). (c) Using a brass bar and hammer, stake the claw wash– ers. SR–71 STEERING – POWER STEERING 15. INSTALL RACK BOOTS (a) Ensure that the tube hole is not clogged with grease. HINT: If the tube hole is clogged, the pressure inside the boot will change after it is assembled and the steering wheel turned. (b) Install the boots. HINT: Be careful not to damage or twist the boot. (c) install the clamps and clips. 16. INSTALL TIE ROD ENDS (a) Screw the lock nuts and tie rod ends onto the rack ends until the matchmarks are aligned. (b) After adjusting toe–in, torque the lock nut. Torque: 74 N–m (750 kgf–cm, 54 ft–lbf) 17. INSTALL RIGHT AND LEFT TURN PRESSURE TUBES (a) Install new O–rings to the tube. (b) Using SST, install and torque the tubes. SST 09633–00020 Torque: 11 N–m (110 kgf–cm, 8 ft–lbf) HINT: Use a torque wrench with a fulcrum length of 300 mm (11.81 in.). SR–72 STEERING – SERVICE SPECIFICATIONS SERVICE DATA Steering wheel freeplay (Maximum) PS ON–VEHICLE INSPECTION Drive belt tension 1 MZ– FE (New belt) Drive belt tension 1 MZ–FE (Used belt) Drive belt tension 5S–FE (New belt) Drive belt tension 5S–FE (Used belt) Maximum rise of oil level Oil pressure at idle speed with valve closed (Minimum) 1 MZ–FE Oil pressure at idle speed with valve closed (Minimum) 5S–FE Steering effort at idle speed (Maximum) PS PUMP Rotor shaft bushing oil clearance (STD) 1 MZ– FE Rotor shaft bushing oil clearance (Maximum) 1 MZ–FE Vane plate to rotor groove clearance (Maximum) 1 MZ–FE Rotor shaft bushing oil clearance (STD) 5S–FE Rotor shaft bushing oil clearance (Maximum) 5S–FE Vane plate to rotor groove clearance (Maximum) 5S–FE Vane plate length (Minimum) 1 MZ–FE for PS Vane plate height (Minimum) 1 MZ–FE for PS Vane plate thickness (Minimum) 1 MZ–FE for PS Vane plate length (Minimum) 1 MZ–FE for Hydraulic cooling fan Vane plate height (Minimum) 1 MZ–FE for Hydraulic cooling fan Vane plate thickness (Minimum) 1 MZ–FE for Hydraulic cooling fan Vane plate length (Minimum) 5S–FE Vane plate height (Minimum) 5S–FE Vane plate thickness (Minimum) 5S–FE Vane plate length 1 MZ–FE for PS (Cam ring mark) (Rotor mark) Vane plate length 1 MZ–FE for Hydraulic cooling fan (Cam ring mark) (Rotor mark) Vane plate length 5S–FE (Cam ring and rotor mark) None SERVICE SPECIFICATIONS SR–73 STEERING Flow control valve spring length (STD) 1 MZ–FE Flow control valve spring length (Minimum) 1 MZ–FE Flow control valve spring length (STD) 5S–FE Flow control valve spring length (Minimum) 5S–FE Pump rotating torque (Maximum) PS GEAR HOUSING Steering rack runout (Maximum) Total preload (Turning) TORQUE SPECIFICATIONS Part tightened STEERING COLUMN Steering main shaft x Sliding yoke Column bracket x Body Steering wheel Wheel pad Tilt lever x Column tube POWER STEERING PUMP FOR 1 MZ–FE Pressure port union x Pump housing Suction port union x Pump housing Front housing x Rear housing Control valve assy Pump puIly x Pump shaft Pressure tube x Pressure port union PS pump installation bolt POWER STEERING PUMP FOR 5S–FE Pressure port union x Pump housing Suction port union x Pump housing Pump puIly x Pump shaft PS pump installation bolt (Adjusting bolt) PS pump installation bolt (Through bolt) PS pump x Pressure tube POWER STEERING GEAR HOUSING Control valve housing x Rack housing Control valve self–locking nut Rack housing cap Lock nut Rack x Rack end Tie rod end lock nut Turn pressure tube union nut Gear housing x Sub frame Control valve shaft x Sliding yoke Pressure and return tube x Gear housing Tie rod end x Steering knuckle – SERVICE SPECIFICATIONS ST–1 STARTING SYSTEM – STARTING SYSTEM ST–2 STARTING SYSTEM – (5S–FE) (5S–FE) DESCRIPTION The starter is a reduction type with a small, high–speed motor used to drive the pinion gear. ST–3 STARTING SYSTEM – (5S–FE) SYSTEM CIRCUIT OPERATION When the ignition switch is turned to START position, current flows from terminal 50 to the coil of the solenoid and the plunger is pulled by the magnetic force of the coil. When the plunger is pulled to the left, the contact plate of the plunger allows current from the battery to flow directly from terminal 30 to the motor, and the starter rotates. When the engine is running and the ignition switch is returned to ON, the magnetic force of the coil disappears and the contact plate of the plunger is returned to its original position by the return spring. Battery voltage no longer flows from terminal 30, so the motor stops. ST–4 STARTING SYSTEM – (5S–FE) PREPARATION SST (SPECIAL SERVICE TOOLS) 09286–46011 Injection Pump Spline Shaft Puller Armature bearing 09820–00030 Alternator Rear Bearing Replacer Armature front bearing RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester set EQUIPMENT Dial indicator Commutator Magnetic finger Pull scale Brush spring Sandpaper Commutator Torque wrench V – block Vernier calipers ON–VEHICLE INSPECTION NOTICE: Before changing the starter, check the following Items again: • Connector connection • Accessory Installation, e.g.: theft deterrent system Commutator, Brush ST–5 STARTING SYSTEM – (5S–FE) STARTER COMPONENTS FOR REMOVAL AND INSTALLATION STARTER REMOVAL 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (–) terminal cable Is discon– nected from the battery. 2. w/ CRUISE CONTROL SYSTEM: REMOVE BATTERY ST–6 STARTING SYSTEM – (5S–FE) 3. w/ CRUISE CONTROL SYSTEM: REMOVE CRUISE CONTROL ACTUATOR (a) Remove the actuator cover. (b) Disconnect the actuator connector. (c) Remove the 3 bolts and cruise control actuator. 4. REMOVE STARTER (a) Disconnect the starter connector. (b) Remove the nut, and disconnect the starter wire. (c) Remove the 2 bolts and starter. ST–7 STARTING SYSTEM – (5S – FE) COMPONENTS FOR DISASSEMBLY AND ASSEMBLY ST–8 STARTING SYSTEM – (5S–FE) STARTER DISASSEMBLY (See Components for Disassembly and Assembly) 1. REMOVE DUST PROTECTOR 2. REMOVE FIELD FRAME AND ARMATURE (a) Remove the nut, and disconnect the lead wire from the magnetic switch terminal. (b) Remove the 2 through bolts, and pull out the field frame together with the armature. (c) Remove the O–ring from the field frame. 3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR (a) Remove the 2 screws. (b) (1) (2) (3) (4) Remove the following parts from the magnetic switch: Starter housing and clutch assembly Return spring Idler gear Bearing 4. REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole. ST–9 STARTING SYSTEM – (5S–FE) REMOVE BRUSH HOLDER (a) Remove the 2 screws, 2 O–rings and end cover from the field frame. (b) Remove the O–ring from the field frame. (c) Using a screwdriver, hold the spring back and discon– nect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder. 6. REMOVE ARMATURE FROM FIELD FRAME STARTER INSPECTION AND REPAIR Armature Coil 1. INSPECT COMMUTATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segment, replace the armature. 2. INSPECT COMMUTATOR FOR GROUND Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature. ST–10 STARTING SYSTEM – (5S–FE) Commutator 1. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES If the surface is dirty or burnt, correct it with sandpa– per (No.400) or on a lathe. 2. INSPECT COMMUTATOR CIRCLE RUNOUT (a) Place the commutator on V – blocks. (b) Using a dial gauge, measure the circle runout. Maximum circle runout: 0.05 mm (0.0020 in.) If the circle runout is greater than maximum, correct it on a lathe. 3. INSPECT COMMUTATOR4R DIAMETER Using a vernier caliper, measure the commutator di– ameter. Standard diameter: 30 mm (1.18 In.) Minimum diameter: 29 mm (1.14 in.) If the diameter is less than minimum, replace the armature. 4. INSPECT UNDERCUT DEPTH Check that the undercut depth is clean and free of foreign materials. Smooth out the edge. Standard undercut depth: 0.6 mm (0.024 in.) Minimum undercut depth: 0.2 mm 10.008 In.) If the undercut depth is less than minimum, correct it with a hacksaw blade. Field Frame (Field Coil) 1. INSPECT FIELD COIL FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the field frame. ST–11 STARTING SYSTEM – (5S–FE) 2. INSPECT FIELD COIL FOR GROUND Using an ohmmeter, check that there is no continuity between the field coil end and field frame. If there is continuity, repair or replace the field frame. Brushes INSPECT BRUSH LENGTH Using a vernier caliper, measure the brush length. Standard length: 15.5 mm (O.610 In.) Minimum length: 8.5 mm (0.335 in.) If the length is less than minimum, replace the brush holder and field frame. Brush Springs INSPECT BRUSH SPRING LOAD Take the pull scale reading the instant the brush spring separates from the brush. Spring installed load: 18–24N(1.79–2.41kgf,3.9–5.31bf) If the installed load is not within specification, replace the brush springs. Brush Holder INSPECT BRUSH HOLDER INSULATION Using an ohmmeter, check that there is no continuity between the positive (+).and negative (–) brush hol– ders. If there is continuity, repair or replace the brush holder. ST–12 STARTING SYSTEM – (5S– FE) Clutch and Gears 1. INSPECT GEAR TEETH Check the gear teeth on the pinion gear, idle gear and clutch assembly for wear or damage. If damaged, replace the gear or clutch assembly. If damaged, also check the drive plate ring gear for wear or damage. 2. INSPECT CLUTCH PINION GEAR Hold the starter clutch and rotate the pinion gear counterclockwise, and check that it turns freely. Try to rotate the pinion gear clockwise and check that it locks. If necessary, replace the clutch assembly. 3. IF NECESSARY, REPLACE CLUTCH ASSEMBLY A. Disassemble starter housing and clutch assembly (a) Mount a brass bar in a vise, and install the starter housing and clutch assembly to the brass bar. (b) Push down the pinion gear. (c) Using a plastic–faced hammer, tap down the stop collar. (d) Using a screwdriver, pry out the snap ring. ST–13 STARTING SYSTEM (e) (1) (2) (3) – (5S–FE) Remove the following parts: Stop collar Pinion gear Compression spring (f) Push down the starter housing, and remove the spring retainer. (g) (1) (2) (3) (4) Disassemble the following parts: Starter housing Starter clutch Compression spring Clutch shaft B. Assemble starter housing and clutch assembly (a) Assemble the following parts: (1) Starter housing (2) Starter clutch (3) Compression spring (4) Clutch shaft (b) Mount a brass bar in a vise, install the starter housing and clutch assembly to the brass bar. ST–14 STARTING SYSTEM – (5S–FE) (c) Push down the starter housing, and install the follow– ing parts: (1) Spring retainer (2) Compression spring (3) Pinion gear (4) Stop collar (d) Push down the pinion gear. (e) Using snap ring pliers, install a new snap ring. (f) Using pliers, compress the snap ring. (g) Check that the snap ring fits correctly. (h) Remove the starter housing and clutch assembly from the brass bar. (i) Using a plastic–faced hammer, tap the clutch shaft and install the stop collar onto the snap ring. Bearings 1. INSPECT REAR BEARINGS Turn each bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing. ST–15 STARTING SYSTEM – (5S–FE) 2. IF NECESSARY, REPLACE REAR BEARING (a) Using SST, remove the bearing. SST 09286–46011 (b) Using a press, press in a new front bearing. 3. INSPECT FRONT BEARING Turn each bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing. 4. IF NECESSARY, REPLACE FRONT BEARING (a) Using SST, remove the bearing. SST 09286 – 46011 (b) Using SST and a press, press in a new bearing. NOTICE: Be careful of the bearing Installation direction. SST 09820–00030 ST–16 STARTING SYSTEM – (5S– FE) Magnetic Switch 1. PERFORM PULL–IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, replace the magnetic switch. 2. PERFORM HOLD–IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnetic switch. STARTER ASSEMBLY (See Components for Disassembly and Assembly) HINT: Use high–temperature grease to lubricate the bearings and gears when assembling the starter. 1. PLACE ARMATURE INTO FIELD FRAME Apply grease to the armature bearings, and insert the armature into the field frame. 2. INSTALL BRUSH HOLDER (a) Place the brush holder in position on the armature. (b) Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder. Connect the 4 brushes. NOTICE: Check that the positive (+) lead wires are not grounded. (c) Place a new O–ring in position on the field frame. ST–17 STARTING SYSTEM – (5S–FE) (d) Install a new O–ring to the screw. (e) Install the end cover to the field frame with the 2 screws. Torque: 1.5 N⋅m (15 kgf⋅cm, 13 in.⋅Ibf) 3. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE (a) Apply grease to the steel ball. (b) Insert the steel ball into the clutch shaft hole. 4. INSTALL STARTER HOUSING, CLUTCH ASSEM– BLY AND GEAR (a) Apply grease to the return spring. (b) Insert the return spring into the magnetic switch hole. (c) Place the following parts in position on the starter housing: (1) Idler gear (2) Retainer (d) Install the starter housing to the magnetic switch with the 2 screws. Torque: 5.9 N⋅m (60 kgf⋅cm. 62 in.⋅lbf) ST–18 STARTING SYSTEM – (5S– FE) 5. INSTALL FIELD FRAME AND ARMATURE ASSEMBLY (a) Place a new O–ring in position on the field frame. (b) Align the protrusion of the field frame with the cutout of the magnetic switch. (c) Install the field frame and armature assembly with the 2 through bolts. Torque: 6.9 N⋅m (60 kgf⋅cm, 52 in.⋅lbf) (d) Connect the lead wire to terminal C, and install the nut. Torque: 7.9 N⋅m (81 kgf⋅cm, 70 In.⋅Ibf) 6. INSTALL DUST PROTECTOR ST–19 STARTING SYSTEM – (5S–FE) STARTER PERFORMANCE TEST NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. 1. PERFORM PULL–IN TEST (a) Disconnect the field coil lead wire from terminal C. (b) Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward. If the clutch pinion gear does not move, replace the magnetic switch assembly. 2. PERFORM HOLD–IN TEST With battery connected as above with the clutch pinion gear out, disconnect the negative (–) lead from terminal C. Check that the pinion gear remains out. If the clutch pinion gear returns inward, replace the magnetic switch assembly. 3. INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative (–) lead from the switch body. Check that the clutch pinion gear returns inward. If the clutch pinion gear does not return, replace the magnetic switch assembly. 4. PERFORM NO–LOAD PERFORMANCE TEST (a) Connect the battery and ammeter to the starter as shown. (b) Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the am– meter shows the specified current. Specified current: 90 A or less at11.6V ST–20 STARTING SYSTEM – (5S–FE) STARTER INSTALLATION (See Components for Removal and Installation) 1. INSTALL STARTER (a) Install the starter with the 2 bolts. Torque: 39 N⋅m (400 kgf⋅cm, 29 ft⋅lbf) (b) Connect the starter wire with the nut. (c) Connect the starter connector. 2. w/ CRUISE CONTROL SYSTEM: INSTALL CRUISE CONTROL ACTUATOR (a) Install the cruise control actuator with the 3 bolts. (b) Connect the actuator connector. (c) Install the actuator cover. 3. w/ CRUISE CONTROL SYSTEM: INSTALL BATTERY 4. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 6. CHECK THAT ENGINE STARTS ST–21 STARTING SYSTEM – (5S–FE) STARTER RELAY STARTER RELAY INSPECTION 1. REMOVE STARTER RELAY 2. INSPECT STARTER RELAY A. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. (b) Check that there is no continuity between terminals 3 and 5. If continuity is not as specified, replace the relay. B. Inspect relay operation (a) Apply battery voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 3. REINSTALL STARTERT RELAY ST–22 STARTING SYSTEM – (5S–FE) CLUTCH START SWITCH (M/T) (See page CL–7) PARK/NEUTRAL POSITION (PNP) SWITCH (A/T) (See page AX–92) SERVICE SPECIFICATIONS SERVICE DATA Starter Rated voltage and output power No–load characteristics Brush length Spring installed load Commutator Diameter Undercut depth Circle runout TORQUE SPECIFICATIONS Pert tightened End cover x Brush holder Starter housing x Magnetic switch End cover x Starter housing (Through bolt) Lead wire x Terminal C of starter Starter x Transaxle ST–23 STARTING SYSTEM – (1MZ – FE) (1 MZ–FE) DESCRIPTION The starter is a reduction type with a small, high–speed motor used to drive the pinion gear. ST–24 STARTING SYSTEM – (1MZ – FE) SYSTEM CIRCUIT OPERATION When the ignition switch is turned to START position, current flows from terminal 50 to the coil of the solenoid and the plunger is pulled by the magnetic force of the coil. When the plunger is pulled to the left, the contact plate of the plunger allows current from the battery to flow directly from terminal 30 to the motor, and the starter rotates. When the engine is running and the ignition switch is returned to ON, the magnetic force of the coil disappears and the contact plate of the plunger is returned to its original position by the return spring. Battery voltage no longer flows from terminal 30, so the motor stops. ST–25 STARTING SYSTEM – (1MZ – FE) PREPARATION SST (SPECIAL SERVICE TOOLS) 09286–46011 Injection Pump Spline Shaft Puller Armature bearing 09820–00030 Alternator Rear Bearing Replacer Armature front bearing RECOMMENDED TOOLS 09082–00050 TOYOTA Electrical Tester set EQUIPMENT Dial indicator Commutator Magnetic finger Steel bell Pull scale Brush spring Sandpaper Commutator Torque wrench V–block Commutator Vernier calipers Commutator, Brush ON –VEHICLE INSPECTION NOTICE: Before changing the starter, check the following items again: • Connector connection • Accessory installation, e.g.: theft deterrent system ST–26 STARTING SYSTEM – (1MZ – FE) STARTER COMPONENTS FOR REMOVAL AND INSTALLATION STATER REMOVAL (See Components for Removal and installation) 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (–) terminal cable is dis– connected from the battery. 2. w/ CRUISE CONTROL SYSTEM: REMOVE BATTERY AND TRAY ST–27 STARTING SYSTEM – (1MZ – FE) 3. w/ CRUISE CONTROL SYSTEM: REMOVE CRUISE CONTROL ACTUATOR (a) Remove the bolt, clip and actuator cover. (b) Disconnect the actuator connector and clamp. (c) Remove the 3 bolts, and disconnect the actuator with the bracket. 4. REMOVE STARTER (a) Disconnect the starter connector. (b) Remove the nut, and disconnect the starter wire. (c) Remove the 2 bolts and starter. ST–28 STARTING SYSTEM – (1MZ – FE) COMPONENTS FOR DISASSEMBLY AND ASSEMBLY ST–29 STARTING SYSTEM – (1MZ – FE) STARTER DISASSEMBLY (See Components for Disassembly and Assembly) 1. REMOVE DUST PROTECTOR 2. REMOVE FIELD FRAME AND ARMATURE (a) Remove the nut, and disconnect the lead wire from the magnetic switch terminal. (b) Remove the 2 through bolts, and pull out the field frame together with the armature. (c) Remove the O–ring from the field frame. 3. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR (a) Remove the 2 screws. (b) (1) (2) (3) (4) Remove the following parts from the magnetic switch: Starter housing and clutch assembly Return spring Idler gear Bearing 4. REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole. ST–30 STARTING SYSTEM – (1MZ – FE) 5. REMOVE BRUSH HOLDER (a) Remove the 2 screws, 2 O–rings and end cover from the field frame. (b) Remove the O–ring from the field frame. (c) Using a screwdriver, hold the spring back and discon– nect the brush from the brush holder. Disconnect the 4 brushes, and remove the brush holder. 6. REMOVE ARMATURE FROM FIELD FRAME STARTER INSPECTION AND REPAIR Armature Coil 1. INSPECT COMMUTATOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the segments of the commutator. If there is no continuity between any segment, replace the armature. 2. INSPECT COMMUTATOR FOR GROUND Using an ohmmeter, check that there is no continuity between the commutator and armature coil core. If there is continuity, replace the armature. ST–31 STARTING SYSTEM – (1MZ – FE) Commutator 1. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe. 2. INSPECT COMMUTATOR CIRCLE RUNOUT (a) Place the commutator on V – blocks. (b) Using a dial gauge, measure the circle runout. Maximum circle runout: 0.05 mm (0.0020 in.) If the circle runout is greater than maximum, correct it on a lathe. 3. INSPECT COMMUTATOR DIAMETER Using a vernier caliper, measure the commutator diameter. Standard diameter: 30.0 mm 0.181 In.) Minimum diameter: 29.0 mm (1.142 In.) If the diameter is less than minimum, replace the armature. 4. INSPECT UNDERCUT DEPTH Check that the undercut depth is clean and free of foreign materials. Smooth out the edge. Standard undercut depth: 0.6 mm (0.024 In.) Minimum undercut depth: 0.2 mm (0.008 In.) If the undercut depth is less than minimum, correct it with a hacksaw blade. Field Frame (Field Coil) 1. INSPECT FIELD COIL FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the field frame. ST–32 STARTING SYSTEM – (1MZ – FE) 2. INSPECT FIELD COIL FOR GROUND Using an ohmmeter, check that there is no continuity between the field coil end and field frame. If there is continuity, repair or replace the field frame. Brushes INSPECT BRUSH LENGTH Using a vernier caliper, measure the brush length. Standard length: 15.5 mm (O.610 In.) Minimum length: 8.5 mm (0.335 In.) If the length is less than minimum, replace the brush holder and field frame. Brush Springs INSPECT BRUSH SPRING LOAD Take the pull scale reading the instant the brush spring separates from the brush. Spring installed load: 18 – 24 N (1.79 – 2.41 kgf. 3.9 – 5.3 Ibf) If the installed load is not within specification, replace the brush springs. Brush Holder INSPECT BRUSH HOLDER INSULATION Using an ohmmeter, check that there is no continuity between the positive (+) and negative (–) brush hol– ders. If there is continuity, repair or replace the brush holder. ST–33 STARTING SYSTEM – (1MZ – FE) Clutch and Gears 1. INSPECT GEAR TEETH Check the gear teeth on the pinion gear, idler gear and clutch assembly for wear or damage. If damaged, replace the gear or clutch assembly. If damaged, also check the drive plate ring gear for wear or damage. 2. INSPECT CLUTCH PINION GEAR Hold the starter clutch and rotate the pinion gear counterclockwise, and check that it turns freely. Try to rotate the pinion gear clockwise and check that it locks. If necessary, replace the clutch assembly. 3. IF NECESSARY, REPLACE CLUTCH ASSEMBLY A. Disassembly of starter housing and clutch assembly (a) Mount a brass bar in a vise, and install the starter housing and clutch assembly to the brass bar. (b) Push down the pinion gear. (c) Using a plastic–faced hammer, tap down the stop collar. (d) Using a screwdriver, pry out the snap ring. ST–34 STARTING SYSTEM (e) (1) (2) (3) – (1MZ – FE) Remove the following parts: Stop collar Pinion gear Compression spring (f) Push down the starter housing, and remove the spring retainer. (g) (1) (2) (3) (4) Disassemble the following parts: Starter housing Starter clutch Compression spring Clutch shaft B. Assemble starter housing and clutch assembly (a) Assemble the following parts: (1) Starter housing (2) Starter clutch (3) Compression spring (4) Clutch shaft (b) Mount a brass bar in a vise, install the starter housing and clutch assembly to the brass bar. ST–35 STARTING SYSTEM – (1MZ – FE) (c) Push down the starter housing, and install the follow– ing parts: (1) Spring retainer (2) Compression spring (3) Pinion gear (4) Stop collar (d) Push down the pinion gear. (e) Using snap ring pliers, install a new snap ring. (f) Using pliers, compress the snap ring. (g) Check that the snap ring fits correctly. (h) Remove the starter housing and clutch assembly from the brass bar. (i) Using a plastic–faced hammer, tap the clutch shaft and install the stop collar onto the snap ring. Bearings 1. INSPECT REAR BEARINGS Turn each bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing. ST–36 STARTING SYSTEM – (1MZ – FE) 2. IF NECESSARY, REPLACE REAR BEARING (a) Using SST, remove the bearing. SST 09286–46011 (b) Using a press, press in a new front bearing. 3. INSPECT FRONT BEARING Turn each bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing. 4. IF NECESSARY, REPLACE FRONT BEARING (a) Using SST, remove the bearing. SST 09286–46011 (b) Using SST and a press, press in a new bearing. NOTICE: Be careful of the bearing Installation direction. SST 09820–00030 ST–37 STARTING SYSTEM – (1MZ – FE) Magnetic Switch 1. PERFORM PULL–IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, replace the magnetic switch. 2. PERFORM HOLD –IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnetic switch. STARTER ASSEMBLY (See Components for Disassembly and Assembly) HINT: Use high –temperature grease to lubricate the bearings and gears when assembling the starter. 1. PLACE ARMATURE INTO FIELD FRAME Apply grease to the armature bearings, and insert the armature into the field frame. 2. INSTALL BRUSH HOLDER (a) Place the brush holder in position on the armature. (b) Using a screwdriver, hold the brush spring back, and connect the brush into the brush holder. Connect the 4 brushes.. NOTICE: Check that the positive (+) load wires are not grounded. (c) Place a new O–ring in position on the field frame. ST–38 STARTING SYSTEM – (1MZ – FE) (d) Install a new 0 – ring to the screw. (e) Install the end cover to the field frame with the 2 screws. Torque: 1.5 N⋅m (15 kgf⋅cm, 13 in.⋅Ibf) 3. INSERT STEEL BALL INTO CLUTCH SHAFT HOLE (a) Apply grease to the steel ball. (b) Insert the steel ball into the clutch shaft hole. 4. INSTALL STARTER HOUSING, CLUTCH ASSEM– BLY AND GEAR (a) Apply grease to the return spring. (b) Insert the return spring into the magnetic switch hole. (c) Place the following parts in position on the starter housing: (1) Idler gear (2) Retainer (d) Install the starter housing to the magnetic switch with the 2 screws. Torque: 5.9 N⋅m (60 kgf⋅cm, 52 In.⋅Ibf) ST–39 STARTING SYSTEM – (1MZ – FE) 5. INSTALL FIELD FRAME AND ARMATURE ASSEMBLY (a) Place a new 0 – ring in position on the field frame. (b) Align the protrusion of the field frame with the cutout of the magnetic switch. (c) Install the field frame and armature assembly with the 2 through bolts. Torque: 5.9 N⋅m (60 kgf⋅cm. 52 in.⋅Ibf) (d) Connect the lead wire to terminal C, and install the nut. Torque: 7.9 N⋅m (87 kgf⋅cm, 70 in.⋅lbf) ST–40 STARTING SYSTEM – (1MZ – FE) STARTER PERFORMANCE TEST NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. 1. PERFORM PULL–IN TEST (a) Disconnect the field coil lead wire from terminal C. (b) Connect the battery to the magnetic switch as shown. Check that the clutch pinion gear moves outward. If the clutch pinion gear does not move, replace the magnetic switch assembly. 2. PERFORM HOLD–IN TEST With battery connected as above with the clutch pinion gear out, disconnect the negative (–) lead from terminal C. Check that the pinion gear remains out. If the clutch pinion gear returns inward, replace the magnetic switch assembly. 3. INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative (–) lead from the switch body. Check that the clutch pinion gear returns inward. If the clutch pinion gear does not return, replace the magnetic switch assembly. 4. PERFORM NO –LOAD PERFORMANCE TEST (a) Connect the battery and ammeter to the starter as shown. (b) Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the am– meter shows the specified current. Specified current: 90 A or less at 11.5 V ST–41 STARTING SYSTEM – (1MZ – FE) STARTER INSTALLATION (See Components for Remove and Installation) 1. INSTALL STARTER (a) Install the starter with the 2 bolts. Torque: 39 N⋅m (400 kgf⋅cm. 29 ft⋅lbf) (b) Connect the starter wire with the nut. (c) Connect the starter connector. 2. w/ CRUISE CONTROL SYSTEM: INSTALL CRUISE CONTROL ACTUATOR (a) Connect the actuator and bracket with the 3 bolts. (b) Connect the actuator connector and clamp. (c) Install the actuator cover with the bolt and clip. 3. w/ CRUISE CONTROL SYSTEM: INSTALL BATTERY TRAY AND BATTERY 4. CONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY 5. CHECK THAT ENGINE STARTS ST–42 STARTING SYSTEM – (1MZ – FE) STARTER RELAY STARTER RELAY INSPECTION 1. DISCONNECT NEGATIVE (–) TERMINAL CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch Is turned to the ’LOCK’ position and the negative (–) terminal cable is discon– nected from the battery. 2. REMOVE STARTER RELAY LOCATION: In the engine compartment relay box. Remove the relay box cover and starter relay. 3. INSPECT STARTER RELAY A. Inspect relay continuity (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. (b) Check that there is no continuity between terminals 3 and 5. If continuity is not as specified, replace the relay. B. Inspect relay operation (a) Apply battery voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 4. REINSTALL STARTER RELAY 6. RECONNECT NEGATIVE (–) TERMINAL CABLE TO BATTERY ST–43 STARTING SYSTEM – (1MZ – FE) PARK NEUTRAL POSITION (PNP) SWITCH (See page AX–116) SERVICE SPECIFICATIONS SERVICE DATA Starter Rated voltage and output power No–load characteristics Brush length Spring installed load Commutator Diameter Undercut depth Circle runout TORQUE SPECIFICATIONS Part tightened End cover x Field frame Starter housing x Magnetic switch Field frame x Armature assembly Lead wire x Terminal C of starter Starter mounting bolt FOREWORD This wiring diagram manual has been prepared to provide information on the electrical system of the 1994 TOYOTA CAMRY. Applicable models: SXV10 Series MCV10 Series For service specifications and repair procedures of the above models other than those listed in this manual, refer to the following manuals; Pub. No. Manual Name  1994 CAMRY Repair Manual Volume 1 Volume 2  1994 Model New Car Features RM361U1 RM361U2 NCF099U All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice. TOYOTA MOTOR CORPORATION NOTICE When handling supplemental restraint system components (removal, installation or inspection, etc.), always follow the direction given in the repair manuals listed above to prevent accidents and supplemental restraint system malfunction. 1 INTRODUCTION This manual consists of the following 11 sections: No. Section Description INDEX Index of the contents of this manual. INTRODUCTION Brief explanation of each section. B HOW TO USE THIS MANUAL Instructions on how to use this manual. C TROUBLE– SHOOTING Describes the basic inspection procedures for electrical circuits. D ABBREVIATIONS Defines the abbreviations used in this manual. E GLOSSARY OF TERMS AND SYMBOLS Defines the symbols and functions of major parts. F RELAY LOCATIONS Shows position of the Electronic Control Unit, Relays, Relay Block, etc. This section is closely related to the system circuit. G ELECTRICAL WIRING ROUTING Describes position of Parts Connectors, Splice points, Ground points, etc. This section is closely related to the system circuit. H POWER SOURCE (Current Flow Chart) Describes power distribution from the power supply to various electrical loads. INDEX Index of the system circuits. SYSTEM CIRCUITS Electrical circuits of each system are shown from the power supply through ground points. Wiring connections and their positions are shown and classified by code according to the connection method. (Refer to the section, “How to use this manual”). The “System Outline” and “Service Hints” useful for troubleshooting are also contained in this section. J GROUND POINTS Shows ground positions of all parts described in this manual. K OVERALL WIRING DIAGRAM Provides circuit diagrams showing the circuit connections. A I 2 HOW TO USE THIS MANUAL This manual provides information on the electrical circuits installed on vehicles by dividing them into a circuit for each system. The actual wiring of each system circuit is shown from the point where the power source is received from the battery as far as each ground point. (All circuit diagrams are shown with the switches in the OFF position.) When troubleshooting any problem, first understand the operation of the circuit where the problem was detected (see System Circuit section), the power source supplying power to that circuit (see Power Source section), and the ground points (see Ground Points section). See the System Outline to understand the circuit operation. When the circuit operation is understood, begin troubleshooting of the problem circuit to isolate the cause. Use Relay Location and Electrical Wire Routing sections to find each part, junction block and wiring harness connectors, wiring harness and wiring harness connectors, splice points, and ground points of each system circuit. Internal wiring for each junction block is also provided for better understanding of connection within a junction block. Wiring related to each system is indicated in each system circuit by arrows (from , to ). When overall connections are required, see the Overall Wiring Diagram at the end of this manual. 3 HOW TO USE THIS MANUAL * The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. 4 A : System Title B : Indicates a Relay Block. No shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Example: C J : Indicates the wiring color. Wire colors are indicated by an alphabetical code. Indicates Relay Block No. 1. : Indicates the connector to be connected to a part (the numeral indicates the pin No.) B = Black L BR = Brown LG = Light Green V G = Green O = Orange W = White P = Pink Y GR = Gray Explanation of pin use. = Blue = Violet = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Example: L–Y (Blue) The pins shown are only for the highest grade, or only include those in the specification. D R = Red K : Connector Color (Yellow) : Indicates a wiring Splice Point (Codes are “E” for the Engine Room, “I” for the Instrument Panel, and “B” for the Body). Example: Connectors not indicated are milky white in color. E F G : ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. : Indicates related system. : Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows ( ). The Location of Splice Point I 5 is indicated by the shaded section. Outside numerals are pin numbers. The first letter of the code for each wiring harness and wiring harness connector(s) indicates the component’s location, e.g., “E” for the Engine Compartment, “I” for the Instrument Panel and Surrounding area, and “B” for the Body and Surrounding area. When more than one code has the first and second letters in common, followed by numbers (e.g., IH1, IH2), this indicates the same type of wiring harness and wiring harness connector. H : Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. I : Junction Block (The number in the circle is the J/B No. and the connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification). L : Page No. M : Indicates a shielded cable. N : Indicates a ground point. The first letter of the code for each ground point(s) indicates the component’s location, e.g., “E” for the Engine Compartment, “I” for the Instrument Panel and Surrounding area, and “B” for the Body and Surrounding area. O : Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order from upper left to lower right Numbered in order from upper right to lower left Example: 3B indicates that it is inside Junction Block No. 3. P : When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. 5 HOW TO USE THIS MANUAL Q SYSTEM OUTLINE WITH THE IGNITION SW TURNED ON, THE CURRENT FLOWS TO TERMINAL 3 OF THE POWER WINDOW MASTER SW, TERMINAL 2 OF THE POWER WINDOW CONTROL RELAY AND TERMINAL 8 OF THE POWER WINDOW SW THROUGH THE DOOR FUSE. 1. DRIVER’S WINDOW “MANUAL UP” OPERATION BY MASTER SW HOLDING MANUAL SW (DRIVER’S) ON “UP” POSITION LOCATED IN POWER WINDOW MASTER SW, THE CURRENT FLOWS TO TERMINAL 5 OF THE POWER WINDOW CONTROL RELAY THROUGH TERMINAL 3 OF THE MASTER SW  TERMINAL 2 TO OPERATE A POWER WINDOW CONTROL RELAY. THUS THE CURRENT INSIDE THE RELAY FLOWS FROM TERMINAL 2 OF THE RELAY  TERMINAL 1  TERMINAL 2 OF THE POWER WINDOW MOTOR  TERMINAL 1  TERMINAL 4 OF THE RELAY  TERMINAL 3  TO GROUND. THE MOTOR TURNS TO ASCENT THE WINDOW. RELEASING THIS SW, THE ROTATION OF MOTOR IS STOPPED AND THE WINDOWS CAN STOP AT WILL POINT. (FOR THE “MANUAL DOWN” OPERATION, CURRENT FLOWS IN THE REVERSE DIRECTION BECAUSE THE TERMINALS WHERE IT FLOWS ARE CHANGED). 2. DRIVER’S WINDOW “AUTO DOWN” OPERATION BY MASTER SW ONCE THE “AUTO DOWN” BUTTON OF THE MASTER SW IS PUSHED, THE CURRENT FLOWS TERMINAL 9 OF THE POWER WINDOW CONTROL RELAY THROUGH TERMINAL 3 OF THE MASTER SW  TERMINALS 8 AND 9 TO OPERATE THE RELAY. THUS THE CURRENT INSIDE THE POWER WINDOW CONTROL RELAY FLOWS FROM TERMINAL 2 OF THE RELAY  TERMINAL 4  TERMINAL 1 OF THE POWER WINDOW MOTOR  TERMINAL 2  TERMINAL 1 OF THE RELAY  TERMINAL 3  TO GROUND. THE MOTOR CONTINUES THE ROTATION ENABLING TO DESCENT THE WINDOW. THE WINDOW DESCENDS TO THE END POSITION. THE CURRENT WILL BE CUT OFF TO RELEASE THE AUTO DOWN FUNCTION BASED ON THE INCREASING CURRENT BETWEEN TERMINAL 2 OF THE RELAY AND TERMINAL 1 IN RELAY. 3. DRIVER’S WINDOW AUTO DOWN RELEASE OPERATION BY MASTER SW HOLDING THE MANUAL SW (DRIVER’S) ON “UP” POSITION IN OPERATING AUTO DOWN. THE CURRENT FROM TERMINAL 3 OF THE MASTER SW PASSING TERMINAL 2 FLOWS TERMINAL 5 OF THE RELAY AND RELEASES THE AUTO DOWN FUNCTION IN THE POWER WINDOW CONTROL RELAY. RELEASING THE HAND FROM SW, WINDOW STOPS AND CONTINUING ON TOUCHING SW, THE FUNCTION SWITCHES TO MANUAL UP OPERATION. 4. PASSENGER’S WINDOW UP OPERATION (MASTER SW) AND WINDOW LOCK SW OPERATION HOLDING PASSENGER’S WINDOW SW (MASTER SW) ON “UP”, THE CURRENT FLOWS FROM TERMINAL 3 OF THE MASTER SW PASSING TERMINAL 6 TO TERMINAL 3 OF THE POWER WINDOW SW (PASSENGER’S)  TERMINAL 4  TERMINAL 2 OF THE MOTOR  TERMINAL 1  TERMINAL 9 OF THE POWER WINDOW SW  TERMINAL 7  TERMINAL 1 OF THE MASTER SW  TERMINAL 4 TO GROUND. THE MOTOR RUNS TO ASCENT THE WINDOW. RELEASING THIS SW, THE ROTATION OF MOTOR IS STOPPED AND WINDOW CAN STOP AT WILL PLACE. SWITCHING THE WINDOW LOCK SW IN “LOCK” POSITION, THE CIRCUIT IS OPENED AND STOPPED THE MOTOR ROTATION. (FOR THE DOWN OPERATION, CURRENT FLOWS IN THE REVERSE DIRECTION BECAUSE THE TERMINALS WHERE IT FLOWS ARE CHANGED). R SERVICE HINTS P2 POWER WINDOW CONTROL RELAY 3–GROUND: ALWAYS CONTINUITY 2–GROUND: APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 5–GROUND: APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION AND MASTER SW AT UP POSITION 8–GROUND: APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION AND MASTER SW AT AUTO DOWN POSITION 9–GROUND: APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION AND MASTER SW AT DOWN OR AUTO DOWN POSITION P 4 POWER WINDOW MASTER SW 4–GROUND: ALWAYS CONTINUITY 3–GROUND: APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION WINDOW LOCK SW OPEN WITH WINDOW LOCK SW AT LOCK POSITION S : PARTS LOCATION CODE SEE PAGE SEE PAGE 21 P4 21 P3 21 P5 21 T : RELAY BLOCKS CODE SEE PAGE 1 U 16 RELAY BLOCK (RELAY BLOCK LOCATION) R/B NO. 1 (INSTRUMENT PANEL LEFT SIDE) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 3B SEE PAGE 14 JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) J/B NO. 3 AND COWL WIRE (INSTRUMENT PANEL LEFT SIDE) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS V CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ID1 26 FRONT DOOR RH WIRE AND COWL WIRE (RIGHT KICK PANEL) IH1 26 FRONT DOOR LH WIRE AND COWL WIRE (LEFT KICK PANEL) : GROUND POINTS W CODE IC X SEE PAGE 24 GROUND POINT LOCATION COWL LEFT : SPLICE POINTS CODE I5 6 CODE P2 SEE PAGE 24 WIRE HARNESSES WITH SPLICE POINTS COWL WIRE CODE P6 SEE PAGE 21 Q : Explains the system outline. R : Indicates values or explains the function for reference during troubleshooting. S : Indicates the reference page showing the position on the vehicle of the parts in the system circuit. Example: Part “P4” (Power Window Master SW) is on page 21 of the manual. * The letter in the code is from the first letter of the part, and the number indicates its order in parts starting with that letter. Example: P 4 Part is 4th in order Power Window Master SW T : Indicates the reference page showing the position on the vehicle of Relay Block Connectors in the system circuit. Example: Connector “1” is described on page 16 of this manual and is installed on the left side of the instrument panel. U : Indicates the reference page showing the position on the vehicle of J/B and Wire Harness in the system circuit. Example: Connector “3B” connects the Cowl Wire and J/B No. 3. It is described on page 14 of this manual, and is installed on the instrument panel left side. V : Indicates the reference page describing the wiring harness and wiring harness connector (the female wiring harness is shown first, followed by the male wiring harness). Example: Connector “ID1” connects the front door RH wire (female) and cowl wire (male). It is described on page 26 of this manual, and is installed on the right side kick panel. W : Indicates the reference page showing the position of the ground points on the vehicle. Example: Ground point “IC” is described on page 24 of this manual and is installed on the cowl left side. X : Indicates the reference page showing the position of the splice points on the vehicle. Example: Splice point “I 5” is on the Cowl Wire Harness and is described on page 24 of this manual. HINT: Junction connector (code: J1, J2, J3, J4, J5, J6, J7) in this manual include a short terminal which is connected to a number of wire harnesses. Always perform inspection with the short terminal installed. (When installing the wire harnesses, the harnesses can be connected to any position within the short terminal grouping. Accordingly, in other vehicles, the same wire harness from a different part.) Wire harness sharing the same short terminal grouping have the same color. 7 HOW TO USE THIS MANUAL The “Current Flow Chart” section, describes which parts each power source (fuses, fusible links, and circuit breakers) transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully understood. POWER SOURCE (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. The next page and following pages show the parts to which each electrical source outputs current. POWER SOURCE 8 * The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. The ground points circuit diagram shows the connections from all major parts to the respective ground points. When troubleshooting a faulty ground point, checking the system circuits which use a common ground may help you identify the problem ground quickly. The relationship between ground points ( , , and shown below) can also be checked this way. GROUND POINT * The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION. 9 TROUBLESHOOTING VOLTAGE CHECK (a) Establish conditions in which voltage is present at the check point. Example: (b) – Ignition SW on – Ignition SW and SW 1 on – Ignition SW, SW 1 and Relay on (SW 2 off) Using a voltmeter, connect the negative lead to a good ground point or negative battery terminal, and the positive lead to the connector or component terminal. This check can be done with a test light instead of a voltmeter. CONTINUITY AND RESISTANCE CHECK (a) (b) Disconnect the battery terminal or wire so there is no voltage between the check points. Contact the two leads of an ohmmeter to each of the check points. If the circuit has diodes, reverse the two leads and check again. When contacting the negative lead to the diode positive side and the positive lead to the negative side, there should be continuity. When contacting the two leads in reverse, there should be no continuity. (c) 10 Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of the electrical circuit. FINDING A SHORT CIRCUIT (a) Remove the blown fuse and disconnect all loads of the fuse. (b) Connect a test light in place of the fuse. (c) Establish conditions in which the test light comes on. Example: – Ignition SW on – Ignition SW and SW 1 on – Ignition SW, SW 1 and Relay on (Connect the Relay) and SW 2 off (or Disconnect SW 2) (d) Disconnect and reconnect the connectors while watching the test light. The short lies between the connector where the test light stays lit and the connector where the light goes out. (e) Find the exact location of the short by lightly shaking the problem wire along the body. CAUTION (a) (b) Do not open the cover or the case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) When replacing the internet mechanism (ECU part) of the digital meter, be careful that no part of your body or clothing comes in contact with the terminals of leads from the IC, etc. of the replacement part (spare part). DISCONNECTION OF MALE AND FEMALE CONNECTORS To pull apart the connectors, pull on the connector itself, not the wire harness. HINT: Check to see what kind of connector you are disconnecting before pulling apart. 11 TROUBLESHOOTING HOW TO REPLACE TERMINAL (with terminal retainer or secondary locking device) 1. PREPARE THE SPECIAL TOOL HINT: To remove the terminal from the connector, please construct and use the special tool or like object shown on the left. 2. DISCONNECT CONNECTOR 3. DISENGAGE THE SECONDARY LOCKING DEVICE OR TERMINAL RETAINER. (a) (b) Locking device must be disengaged before the terminal locking clip can be released and the terminal removed from the connector. Use a special tool or the terminal pick to unlock the secondary locking device or terminal retainer. NOTICE: Do not remove the terminal retainer from connector body. For Non–Waterproof Type Connector HINT: The needle insertion position varies according to the connector’s shape (number of terminals etc.), so check the position before inserting it. “Case 1” Raise the terminal retainer up to the temporary lock position. “Case 2” Open the secondary locking device. 12 For Waterproof Type Connector HINT: Terminal retainer color is according to connector body. different Example: Terminal Retainer: Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black “Case 1” Type where terminal retainer is pulled up to the temporary lock position (Pull Type). Insert the special tool into the terminal retainer access hole ( Mark) and pull the terminal retainer up to the temporary lock position. HINT: The needle insertion position varies according to the connector’s shape (Number of terminals, etc.), so check the position before inserting it. “Case 2” Type which cannot be pulled as far as Power Lock insert the tool straight into the access hole of terminal retainer as shown. 13 TROUBLESHOOTING Push the terminal retainer down to the temporary lock position. (c) 4. Release the locking lug from terminal and pull the terminal out from rear. INSTALL TERMINAL TO CONNECTOR (a) Insert the terminal. HINT: 1. Make sure the terminal is positioned correctly. 2. Insert the terminal until the locking lug locks firmly. 3. Insert the terminal with terminal retainer in the temporary lock position. (b) 5. 14 Push the secondary locking device or terminal retainer in to the full lock position. CONNECT CONNECTOR ABBREVIATIONS ABBREVIATIONS The following abbreviations are used in this manual. ABS ACIS A/C A/T COMB. C/P ECU EFI EGR ESA Ex. FL IAC ISC J/B LH MFI M/T O/D R/B RH RPM S/D SFI SRS SW TEMP. VSV W/G w/ w/o * = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = Anti–Lock Brake System Acoustic Control Induction System Air Conditioning Automatic Transmission Combination Coupe Electronic Control Unit Electronic Fuel Injection Exhaust Gas Recirculation Electronic Spark Advance Except Fusible Link Idle Air Control Idle Speed Control Junction Block Left-Hand Multiport Fuel Injection Manual Transmission Overdrive Relay Block Right–Hand Engine Speed Sedan Sequential Multiport Fuel Injection Supplemental Restraint System Switch Temperature Vacuum Switching Valve Wagon With Without The titles given inside the components are the names of the terminals (terminal codes) and are not treated as being abbreviations. 15 GLOSSARY OF TERMS AND SYMBOLS BATTERY Stores chemical energy and converts it into electrical energy. Provides DC current for the auto’s various electrical circuits. CAPACITOR (Condenser) A small holding unit for temporary storage of electrical voltage. HEADLIGHTS Current flow causes a headlight filament to heat up and emit light. 1. SINGLE A headlight may have either a FILAMENT single (1) filament or a double (2) filament. 2. DOUBLE FILAMENT HORN An electric device which sounds a loud audible signal. CIGARETTE LIGHTER An electric resistance heating element. CIRCUIT BREAKER Basically a reusable fuse, a circuit breaker will heat and open if too much current flows through it. Some units automatically reset when cool, others must be manually reset. IGNITION COIL Converts low–voltage DC current into high–voltage ignition current for firing the spark plugs. DIODE A semiconductor which allows current flow in only one direction. (for Medium Current Fuse) (for High Current Fuse or Fusible Link.) 16 DIODE, ZENER A diode which allows current flow in one direction but blocks reverse flow only up to a specific voltage. Above that potential, it passes the excess voltage. This acts as a simple voltage regulator. LIGHT Current flow through a filament causes the filament to heat up and emit light. DISTRIBUTOR, IIA Channels high–voltage current from the ignition coil to the individual spark plugs. LED (LIGHT EMITTING DIODE) Upon current flow, these diodes emit light without producing the heat of a comparable light. FUSE A thin metal strip which burns through when too much current flows through it, thereby stopping current flow and protecting a circuit from damage. METER, ANALOG Current flow activates a magnetic coil which causes a needle to move, thereby providing a relative display against a background calibration. FUSIBLE LINK A heavy–gauge wire placed in high amperage circuits which burns through on overloads, thereby protecting the circuit. The numbers indicate the cross– section surface area of the wires. GROUND The point at which wiring attaches to the Body, thereby providing a return path for an electrical circuit; without a ground, current cannot flow. FUEL M METER, DIGITAL Current flow activates one or many LED’s, LCD’s, or fluorescent displays, which provide a relative or digital display. MOTOR A power unit which converts electrical energy into mechanical energy, especially rotary motion. RELAY 1. NORMALLY CLOSED 2. NORMALLY OPEN Basically, an electrically operated switch which may be normally closed (1) or open (2). Current flow through a small coil creates a magnetic field which either opens or closes an attached switch. RELAY, DOUBLE THROW A relay which passes current through one set of contacts or the other. SPEAKER An electromechanical device which creates sound waves from current flow. SWITCH, MANUAL 1. NORMALLY OPEN 2. NORMALLY CLOSED Opens and closes circuits, thereby stopping (1) or allowing (2) current flow. RESISTOR An electrical component with a fixed resistance, placed in a circuit to reduce voltage to a specific value. SWITCH, DOUBLE THROW A switch which continuously passes current through one set of contacts or the other. RESISTOR, TAPPED A resistor which supplies two or more different non adjustable resistance values. SWITCH, IGNITION A key operated switch with several positions which allows various circuits, particularly the primary ignition circuit, to become operational. RESISTOR, VARIABLE or RHEOSTAT A controllable resistor with a variable rate of resistance. Also called a potentiometer or rheostat. SENSOR (Thermistor) A resistor which varies its resistance with temperature. SWITCH, WIPER PARK Automatically returns wipers to the stop position when the wiper switch is turned off. SENSOR, ANALOG SPEED Uses magnetic impulses to open and close a switch to create a signal for activation of other components. TRANSISTOR A solidstate device typically used as an electronic relay; stops or passes current depending on the voltage applied at “base.” SHORT PIN Used to provide an unbroken connection within a junction block. SOLENOID An electromagnetic coil which forms a magnetic field when current flows, to move a plunger, etc. WIRES Wires are always (1) NOT CONNECTED drawn as straight lines on wiring diagrams. Crossed wires (1) without a black dot at the junction are not joined; crossed wires (2) with a black dot or octagonal ( ) mark at the junction are spliced (2) SPLICED (joined) connections. 17 RELAY LOCATIONS [Engine Compartment] [Instrument Panel] 18 [Body] [Sedan] [Coupe] [Wagon] 19 RELAY LOCATIONS ,,, ,,, ,,,: J/B No. 1 20 Instrument Panel Left (See Page 18) [J/B No. 1 Inner Circuit] 21 RELAY LOCATIONS ,,, ,,, ,,,: J/B No. 2 22 Engine Compartment Left (See Page 18) [J/B No. 2 Inner Circuit] 23 RELAY LOCATIONS ,,, ,,, ,,,: J/B No. 3 Behind Combination Meter [J/B No. 3 Inner Circuit] 24 (See Page 18) 1 : R/B No. 1 Left Kick Panel (See Page 18) 4 : R/B No. 4 Right Kick Panel (See Page 18) 25 RELAY LOCATIONS 5 : R/B No. 5 Engine Compartment Left (See Page 18) Behind Glove Box (See Page 18) (for 1MZ–FE) 6 : J/B No. 6 (for 5S–FE) 26 7 : R/B No. 7 Near The Battery (See Page 18) 27 ELECTRICAL WIRING ROUTING Position of Parts in Engine Compartment [1MZ–FE] A A A A A A A A 2 A/C Triple Pressure SW (A/C Dual and Single Pressure SW) 3 A/C Magnetic Clutch and Lock Sensor 4 ABS Actuator 5 ABS Actuator 6 ABS Relay 7 ABS Relay 8 ABS Speed Sensor Front LH 9 ABS Speed Sensor Front RH B 2 Brake Fluid Level SW C C C 2 Cruise Control Actuator 17 Camshaft Position Sensor 18 Crankshaft Position Sensor D D 1 Data Link Connector 1 (Check Connector) 2 Distributor E E E 1 EGR Gas Temp. Sensor 2 Electronic Controlled Transmission Solenoid 4 Engine Coolant Temp. Sensor (EFI Water Temp. Sensor) 5 Engine Coolant Temp. Sensor (Water Temp. Sensor) (for Cooling Fan) E 28 F 1 Front Airbag Sensor LH F 2 Front Airbag Sensor RH F 3 Front Clearance Light LH F 4 Front Clearance Light RH F 5 Front Side Marker LH F 6 Front Side Marker RH F 7 Front Turn Signal Light LH F 8 Front Turn Signal Light RH F 9 Front Wiper Motor F 10 Fuse Box F 16 Fuse Box F 18 Fuse Box G G 1 Generator (Alternator) 2 Generator (Alternator) H 1 H 2 H 3 H 4 H 5 H 6 H 11 H 12 Headlight Hi LH Headlight Hi RH Headlight Lo LH Headlight Lo RH Horn LH Horn RH Heated Oxygen Sensor (Bank 1 Sensor 1) Heated Oxygen Sensor (Bank 2 Sensor 1) Position of Parts in Engine Compartment [1MZ–FE] I I I I I I I I I I I I I I I 1 2 4 5 6 7 8 9 15 16 17 18 19 20 21 Idle Air Control Valve (ISC Valve) Igniter Injector No. 1 Injector No. 2 Injector No. 3 Injector No. 4 Injector No. 5 Injector No. 6 Igniter Ignition Coil No. 1 Ignition Coil No. 2 Ignition Coil No. 3 Ignition Coil No. 4 Ignition Coil No. 5 Ignition Coil No. 6 J 6 Junction Connector K K 1 Knock Sensor 1 2 Knock Sensor 2 M 6 Mass Air Flow (Air Flow Meter) N 1 Noise Filter (for Ignition System) O O 1 Oil Pressure SW 6 O/D Direct Clutch Speed Sensor P 1 Park/Neutral Position SW (Neutral Start SW) (A/T) S S S 1 Solenoid Valve (for Hydrauric Motor) 3 Starter 4 Starter T 1 Throttle Position Sensor V V V V V 1 2 3 4 5 W W 1 Washer Motor 2 Water Temp. Sender VSV (for A/C Idle–Up) VSV (for EGR System) VSV (for Fuel Pressure Up) VSV (for Intake Air Control) Vehicle Speed Sensor (Speed Sensor) 29 ELECTRICAL WIRING ROUTING Position of Parts in Engine Compartment [5S–FE] A A A A A A A A A 1 A/C Condenser Fan Motor 2 A/C Triple Pressure SW (A/C Dual and Single Pressure SW) 3 A/C Magnetic Clutch and Lock Sensor 4 ABS Actuator 5 ABS Actuator 6 ABS Relay 7 ABS Relay 8 ABS Speed Sensor Front LH 9 ABS Speed Sensor Front RH B B 1 Back–Up Light SW (M/T) 2 Brake Fluid Level SW C 2 Cruise Control Actuator D D 1 Data Link Connector 1 (Check Connector) 2 Distributor E E E E E F F F F F F F F F F F F F G G 30 1 2 3 4 EGR Gas Temp. Sensor Electronic Controlled Transmission Solenoid Electronic Controlled Transmission Solenoid Engine Coolant Temp. Sensor (EFI Water Temp. Sensor) 5 Water Temp. SW (for Cooling Fan) 1 2 3 4 5 6 7 8 9 10 16 17 18 Front Airbag Sensor LH Front Airbag Sensor RH Front Clearance Light LH Front Clearance Light RH Front Side Marker LH Front Side Marker RH Front Turn Signal Light LH Front Turn Signal Light RH Front Wiper Motor Fuse Box Fuse Box Fuse Box Fuse Box 1 Generator (Alternator) 2 Generator (Alternator) Position of Parts in Engine Compartment [5S–FE] H H H H H H 1 2 3 4 5 6 I I I I I I I I 1 2 3 4 5 6 7 10 Headlight Hi LH Headlight Hi RH Headlight Lo LH Headlight Lo RH Horn LH Horn RH Idle Air Control Valve (ISC Valve) Igniter Ignition Coil Injector No. 1 Injector No. 2 Injector No. 3 Injector No. 4 Intake Air Temp. Sensor (In–Air Temp. Sensor) K 1 Knock Sensor M 1 Manifold Absolute Pressure Sensor (Vacuum Sensor) N 1 Noise Filter (for Ignition System) O O O 1 Oil Pressure SW 2 Oxygen Sensor (Sub) 3 Oxygen Sensor (Main) P 1 Park/Neutral Position SW (Neutral Start SW) (A/T) R 1 Radiator Fan Motor S S 3 Starter 4 Starter T 1 Throttle Position Sensor V V V V 1 2 3 5 W W 1 Washer Motor 2 Water Temp. Sender VSV (for A/C Idle–Up) VSV (for EGR System) VSV (for Fuel Pressure Up) Vehicle Speed Sensor (Speed Sensor) 31 ELECTRICAL WIRING ROUTING Position of Parts in Instrument Panel A A A A A A A A A A 10 11 12 13 14 15 16 17 18 22 A/C Amplifier A/C Evaporator Temp. Sensor A/C SW ABS ECU ABS ECU Airbag Squib (Steering Wheel Pad) Air Inlet Control Servo Motor Air Vent Mode Control Servo Motor Ashtray Illumination Airbag Squib (Front Passenger Airbag Assembly) B B B B B B B 3 4 5 6 7 8 10 Back Door Lock Control SW Blower Motor Blower Resistor Blower SW Buckle SW LH (w/ Power Seat) Buckle SW LH (w/o Power Seat) Buckle SW RH C C C C C C C C C 3 4 5 6 7 8 9 10 11 Center Airbag Sensor Assembly Cigarette Lighter Cigarette Lighter Illumination Clock Clutch Start SW (M/T) Combination Meter Combination Meter Combination Meter Combination Meter 32 C C C C C 12 13 14 15 16 D 3 Data Lik Connector 2 (TDCL (Toyota Diagnostic Communication Link)) 4 Daytime Running Light Relay (Main) 5 Diode (for Cruise Control) 6 Diode (for Idle–Up) 7 Diode (for Courtesy) 8 Door Lock Control Relay) 24 Date Link Connector 3 25 Diode (for Tension Reducer) D D D D D D D E E E E E E E E Combination SW Combination SW Cooling Fan ECU Cruise Control Clutch SW (M/T) Cruise Control ECU 6 Electronic Controlled Transmission Pattern Select SW 7 Engine Control Module (Engine and Electronic Controlled Transmission ECU) (A/T) 8 Engine Control Module (Engine and Electronic Controlled Transmission ECU) (A/T) 9 Engine Control Module (Engine and Electronic Controlled Transmission ECU) (A/T) 10 Engine Control Module (Engine and Electronic Controlled Transmission ECU) (A/T) 11 Engine Control Module (Engine ECU) (M/T) 12 Engine Control Module (Engine ECU) (M/T) 14 Engine Control Module (Engine ECU) (M/T) Position of Parts in Instrument Panel G G 3 Glove Box Light 4 Glove Box Light SW H H 7 Hazard SW 8 Heater Control SW (for Push Control SW Type) or Air Vent Mode Control SW (for Lever Control SW Type) 9 Heated Oxygen Sensor (Bank 1 Sensor 2) H I I I 11 Ignition Key Cylinder Light 12 Ignition SW and Unlock Warning SW 13 Integration Relay J J J J J 1 2 3 4 7 Junction Connector Junction Connector Junction Connector Junction Connector (for SRS System) Junction Connector K 3 Key Interlock Solenoid N N 2 Noise Filter (for Stop Light) 3 Noise Filter (for Stop Light) O 5 O/D Main SW and A/T Indicator Light (Shift Lever) P P P P P P P 2 3 4 5 6 7 8 Parking Brake SW (for 1MZ–FE) Parking Brake SW (for 5S–FE) Power Seat Control SW Power Seat Motor (for Front Vertical Control) Power Seat Motor (for Rear Vertical Control) Power Seat Motor (for Reclining Control) Power Seat Motor (for Slide Control) R R R R R R 2 3 4 5 6 7 Radio and Player (w/ CD Player) Radio and Player (w/o CD Player) Radio and Player (w/o CD Player) Rear Window Defogger SW Remote Control Mirror SW Rheostat S 5 S 8 S 9 S 10 Shift Lock ECU Stereo Component Amplifier Stereo Component Amplifier Stop Light SW 33 ELECTRICAL WIRING ROUTING Position of Parts in Body [Sedan] A A A 19 20 21 ABS Speed Sensor Rear LH ABS Speed Sensor Rear RH Auto Antenna Motor and Relay D D D D D D D D D D D 10 11 12 13 14 15 16 17 18 19 20 D 21 D D 22 23 Door Courtesy Light Front LH Door Courtesy Light Front RH Door Courtesy SW Front LH Door Courtesy SW Front RH Door Courtesy SW Rear LH Door Courtesy SW Rear RH Door Key Cylinder Light and SW Door Key Lock and Unlock SW LH Door Key Lock and Unlock SW RH Door Lock Control SW RH Door Lock Motor and Door Unlock Detection SW Front LH Door Lock Motor and Door Unlock Detection SW Front RH Door Lock Motor Rear LH Door Lock Motor Rear RH F F F F F 11 12 13 14 15 Front Door Speaker LH Front Door Speaker RH Front Tweeter (Speaker) LH Front Tweeter (Speaker) RH Fuel Pump and Sender H 10 High Mount Stop Light I 14 Interior Light L L 1 2 34 License Plate Light Light Failure Sensor L L 3 4 Luggage Compartment Light Luggage Compartment Light SW M M 2 3 M M 4 5 Moon Roof Control Relay Moon Roof Control SW and Personal Light (w/ Moon Roof) Moon Roof Limit SW Moon Roof Motor P P P P 9 10 11 12 P P P P 13 14 15 16 Power Window Control SW Front RH Power Window Control SW Rear LH Power Window Control SW Rear RH Power Window Master SW and Door Lock Control SW LH Power Window Motor Front LH Power Window Motor Front RH Power Window Motor Rear LH Power Window Motor Rear RH R R R R R R R R R R 8 9 10 11 12 13 16 17 20 21 Rear Combination Light LH Rear Combination Light LH Rear Combination Light RH Rear Combination Light RH Rear Speaker LH Rear Speaker RH Rear Window Defogger (+) Rear Window Defogger (–) Remote Control Mirror LH Remote Control Mirror RH V V 8 9 Vanity Light LH Vanity Light RH Position of Parts in Body [Coupe] A A A 19 ABS Speed Sensor Rear LH 20 ABS Speed Sensor Rear RH 21 Auto Antenna Motor and Relay D D D D D D D 10 11 12 13 16 19 26 D Door Courtesy Light Front LH Door Courtesy Light Front RH Door Courtesy SW Front LH Door Courtesy SW Front RH Door Key Cylinder Light and SW Door Lock Control SW RH Door Lock Motor, Door Unlock Detection SW Door Key Lock and Unlock SW LH 27 Door Lock Motor, Door Unlock Detection SW Door Key Lock and Unlock SW RH 28 Door Lock Control SW LH (w/o Power Window) F F F F F 11 12 13 14 15 H 10 High Mount Stop Light I 14 Interior Light D L L L L 1 2 3 4 Front Door Speaker LH Front Door Speaker RH Front Tweeter (Speaker) LH Front Tweeter (Speaker) RH Fuel Pump and Sender License Plate Light Light Failure Sensor Luggage Compartment Light Luggage Compartment Light SW M M M M 2 Moon Roof Control Relay 3 Moon Roof Control SW and Personal Light (w/ Moon Roof) 4 Moon Roof Limit SW 5 Moon Roof Motor P 9 Power Window Control SW Front RH P 12 Power Window Master SW and Door Lock Control SW LH P 13 Power Window Motor Front LH P 14 Power Window Motor Front RH R R R R R R R R R R 8 9 10 11 12 13 16 17 20 21 Rear Combination Light LH Rear Combination Light LH Rear Combination Light RH Rear Combination Light RH Rear Speaker LH Rear Speaker RH Rear Window Defogger (+) Rear Window Defogger (–) Remote Control Mirror LH Remote Control Mirror RH T T 2 Tension Reducer Solenoid LH 3 Tension Reducer Solenoid RH V V 8 Vanity Light LH 9 Vanity Light RH 35 ELECTRICAL WIRING DIAGRAM Position of Parts in Body [Wagon] A A A 19 ABS Speed Sensor Rear LH 20 ABS Speed Sensor Rear RH 21 Auto Antenna Motor and Relay F F F D D D D D D D D D D D 10 11 12 13 14 15 16 17 18 19 20 H 10 High Mount Stop Light D D Door Courtesy Light Front LH Door Courtesy Light Front RH Door Courtesy SW Front LH Door Courtesy SW Front RH Door Courtesy SW Rear LH Door Courtesy SW Rear RH Door Key Cylinder Light and SW Door Key Lock and Unlock SW LH Door Key Lock and Unlock SW RH Door Lock Control SW RH Door Lock Motor and Door Unlock Detection SW Front LH 21 Door Lock Motor and Door Unlock Detection SW Front RH 22 Door Lock Motor Rear LH 23 Door Lock Motor Rear RH F F 11 Front Door Speaker LH 12 Front Door Speaker RH D 36 I 13 Front Tweeter (Speaker) LH 14 Front Tweeter (Speaker) RH 15 Fuel Pump and Sender 14 Interior Light L L L L 1 2 3 4 M M 2 Moon Roof Control Relay 3 Moon Roof Control SW and Personal Light (w/ Moon Roof) 4 Moon Roof Limit SW 5 Moon Roof Motor M M License Plate Light Light Failure Sensor Luggage Compartment Light Luggage Compartment Light SW 9 Power Window Control SW Front RH P 10 Power Window Control SW Rear LH P P P P P 11 Power Window Control SW Rear RH 12 Power Window Master SW and Door Lock Control SW LH 13 Power Window Motor Front LH 14 Power Window Motor Front RH 15 Power Window Motor Rear LH 16 Power Window Motor Rear RH R R R R R R R R R R 8 9 10 11 12 13 16 17 20 21 P Rear Combination Light LH Rear Combination Light LH Rear Combination Light RH Rear Combination Light RH Rear Speaker LH Rear Speaker RH Rear Window Defogger (+) Rear Window Defogger (–) Remote Control Mirror LH Remote Control Mirror RH P V V 8 Vanity Light LH 9 Vanity Light RH ELECTRICAL WIRING DIAGRAM -Memo ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points [1MZ–FE] : Location of Splice Points [1MZ–FE] 38 Connector Joining Wire Harness and Wire Harness CODE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) EB1 ENGINE ROOM MAIN WIRE AND RELAY WIRE (UNDER THE R/B NO. 5) EC1 ENGINE WIRE AND ENGINE ROOM MAIN WIRE (UNDER THE J/B NO. 1) ED1 COWL WIRE AND ENGINE ROOM MAIN WIRE (UNDER THE J/B NO. 1) EE1 SENSOR WIRE AND ENGINE WIRE (SIDE OF FRONT CYLINDER HEAD) EF1 ENGINE WIRE AND COWL WIRE (NEAR THE BRAKE MASTER CYLINDER) 39 ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points [5S–FE] : Location of Splice Points [5S–FE] 40 Connector Joining Wire Harness and Wire Harness CODE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) EA1 ENGINE ROOM MAIN WIRE AND ENGINE ROOM NO. 3 WIRE (RADIATOR FAN SHROUD) EB1 ENGINE ROOM MAIN WIRE AND RELAY WIRE (UNDER THE R/B NO. 5) EC1 ENGINE WIRE AND ENGINE ROOM MAIN WIRE (UNDER THE J/B NO. 1) ED1 COWL WIRE AND ENGINE ROOM MAIN WIRE (UNDER THE J/B NO. 1) EF1 ENGINE WIRE AND COWL WIRE (NEAR THE BRAKE MASTER CYLINDER) 41 ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points 42 Connector Joining Wire Harness and Wire Harness CODE IG1 IH1 IH2 JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) FLOOR NO. 1 WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL) FRONT DOOR LH WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL) II1 COWL WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL) II2 INSTRUMENT PANEL WIRE AND COWL WIRE (BEHIND COMBINATION METER) IJ1 FLOOR NO. 1 WIRE AND COWL WIRE (LEFT KICK PANEL) IK1 COWL WIRE AND A/C SUB WIRE (NEAR THE RADIO AND PLAYER) IL1 COWL WIRE AND SERVO MOTOR SUB WIRE (BEHIND RADIO AND PLAYER) IM1 IM2 IN1 INSTRUMENT PANEL WIRE AND CONSOLE BOX WIRE (NEAR THE RADIO AND PLAYER) INSTRUMENT PANEL WIRE AND SWITCH WIRE (UNDER THE INSTRUMENT PANEL CENTER) 43 ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Splice Points 44 Connector Joining Wire Harness and Wire Harness CODE IO1 JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) FLOOR NO. 1 WIRE AND SEAT WIRE (UNDER THE DRIVER’S SEAT) IP1 IP2 ENGINE WIRE AND COWL WIRE (UNDER THE GLOVE BOX) IP3 IQ1 IR1 IR2 IS1 IT1 IT2 IU1 IV1 IV2 ENGINE WIRE AND INSTRUMENT PANEL WIRE (UNDER THE GLOVE BOX) ENGINE ROOM MAIN WIRE AND COWL WIRE (RIGHT KICK PANEL) FLOOR NO. 2 WIRE AND COWL WIRE (RIGHT KICK PANEL) FRONT DOOR RH WIRE AND INSTRUMENT PANEL WIRE (RIGHT KICK PANEL) FLOOR NO. 2 WIRE AND INSTRUMENT PANEL WIRE (RIGHT KICK PANEL) ROOF WIRE AND COWL WIRE (INSTRUMENT PANEL RIGHT) 45 ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points [Sedan] : Location of Splice Points [Sedan] 46 Connector Joining Wire Harness and Wire Harness CODE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) BW1 REAR DOOR LH WIRE AND FLOOR NO. 1 WIRE (LEFT CENTER PILLAR) BX1 FUEL GAUGE WIRE AND FLOOR NO. 1 WIRE (UNDER THE REAR SEAT CUSHION) BY1 REAR DOOR RH WIRE AND FLOOR NO. 2 WIRE (RIGHT CENTER PILLAR) BZ1 LUGGAGE ROOM NO. 1 WIRE AND FLOOR NO. 1 WIRE (LUGGAGE COMPARTMENT LEFT) Ba1 FLOOR NO. 1 WIRE AND LUGGAGE ROOM NO. 2 WIRE (LUGGAGE COMPARTMENT DOOR) 47 ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points [Coupe] : Location of Splice Points [Coupe] 48 Connector Joining Wire Harness and Wire Harness CODE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) BX1 FUEL GAUGE WIRE AND FLOOR NO. 1 WIRE (UNDER THE REAR SEAT CUSHION) BZ1 LUGGAGE ROOM NO. 1 WIRE AND FLOOR NO. 1 WIRE (LUGGAGE COMPARTMENT LEFT) Ba1 FLOOR NO. 1 WIRE AND LUGGAGE ROOM NO. 2 WIRE (LUGGAGE COMPARTMENT DOOR) 49 ELECTRICAL WIRING ROUTING : Location of Connector Joining Wire Harness and Wire Harness : Location of Ground Points [Wagon] : Location of Splice Points [Wagon] 50 Connector Joining Wire Harness and Wire Harness CODE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) BW1 REAR DOOR LH WIRE AND FLOOR NO. 1 WIRE (LEFT CENTER PILLAR) BX1 FUEL GAUGE WIRE AND FLOOR NO. 1 WIRE (UNDER THE REAR SEAT CUSHION) BY1 REAR DOOR RH WIRE AND FLOOR NO. 2 WIRE (RIGHT CENTER PILLAR) Bb1 LUGGAGE ROOM NO. 1 WIRE AND FLOOR NO. 1 WIRE (LUGGAGE COMPARTMENT LEFT) Bc1 Bc2 BACK DOOR NO. 1 (WIRE AND FLOOR NO. 1 WIRE (LEFT QUARTER TRIM INNER) Bc3 Bd1 Bd2 BACK DOOR NO. 1 WIRE AND BACK DOOR NO. 2 WIRE (BACK DOOR LEFT) Bd3 Be1 REAR WINDOW NO. 1 WIRE AND BACK DOOR NO. 2 WIRE (BACK DOOR LEFT) 51 POWER SOURCE (Current Flow Chart) The chart below shows the route by which current flows from the battery to each electrical source (Fusible Link, Circuit Breaker, Fuse, etc.) and other parts. The next page and following pages show the parts to which each electrical source outputs current. Ignition SW (AM2) 30A AM2 Headlight Relay (Point Side) Headlight Relay (Coil Side) 40A MAIN Starter Relay (Point Side) 7.5A SRS 15A STOP 60A ABS Generator (Alternator) Battery FL MAIN 2.0L Taillight Relay (Coil Side) 100A ALT 7.5A OBD 40A DEFOG 7.5A ALT–S Starter 10A HAZ 40A HEATER 10A HORN Taillight Relay (Point Side) 15A ECU–B 15A EFI Engine Main Relay (Point Side) 15A TEL (5S–FE) 20A DOME 30A POWER 40A AM1 Daytime Running Light Relay No. 2 (Coil Side) Daytime Running Light Relay (Main) (Canada) Daytime Running Light Relay No. 2 (Point Side) [LOCATION] (1) (3) 52 : J/B No. 1 (See page 20 20) : R/B No. 1 (See page 25 20) (2) (7) 15A HEAD (UPR–LH) 15A HEAD (UPR–RH) : J/B No. 2 (See page22 19) : R/B No. 7 (See page 27 19) 7.5A IGN (USA) 15A HEAD (LH) 15A HEAD (RH) (Canada) Daytime Running Light Relay (Main) 7.5A DRL Dimmer SW [Comb. SW] Integration Relay 15A HEAD (LWR–LH) 15A HEAD (LWR–RH) Light Control SW [Comb. SW] (Canada) 10A STARTER (TMM Made) Starter ABS Actuator and ECU ABS Relay ABS Actuator ABS ECU (TMC Made) ABS Relay Integration Relay Light Control SW [Comb. SW] Defogger Relay (Point Side) 10A MIR HTR Heater Relay (Point Side) 10A A/C (M/T) 15A TAIL 30A RDI FAN 30A CDS FAN Power Main Relay (Point Side) Ignition SW (AM1) Starter Relay (Coil Side) Clutch Start SW (A/T) Park/Neutral Position SW (Neutral Start SW) Engine Control Module (Engine and Electronic Controlled Transmission ECU) 7.5A TURN 10A GAUGE 15A ECU–IG 15A CIG/RADIO 20A WIPER * These are the page numbers of the first page on which the related system is shown. The part indicated is located somewhere in the system, not necessarily on the page indicated here. (4) : R/B No. 4 (See page25 20) (5) : R/B No. 5 (See page 26 19) (6) R/B No. 6 (See Page26 ) 53 POWER SOURCE (Current Flow Chart)
40A AM1 15A CIG/RADIO 40A DEFOG 15A ECU–1G 10A GAUGE 7.5A IGN 10A MIR–HTR 30A POWER 7.5A SRS 15A STOP 15A TAIL 7.5A TURN 20A WIPER 30A AM2 7.5A ALT–S 30A CDS FAN 20A DOME 15A ECU–B 15A EFI 10A HAZ 15A HEAD (LWR–LH) 15A HEAD (LWR–RH) 15A HEAD (UPR–LH) 15A HEAD (UPR–RH) 15A HEAD LH 15A HEAD RH 10A HORN 40A MAIN 7.5A OBD 10A STARTER 10A A/C 40A HEATER 7.5A DRL 100A ALT 60A ABS Back Door Lock Motor (W/G) B5 B6 B7 B9 B10 Buckle SW RH Buckle SW LH A/C SW A7 A10 A11 A12 A13 A14 A16 A17 A18 A21 B1 B2 B3 B4 Blower Resistor Blower Motor Back Door Lock Control SW Brake Fluid Level SW Back–Up Light SW (M/T) Auto Antenna Motor and Relay Ashtray Illumination Air Vent Mode Control Servo Motor Air Inlet Control Servo Motor ABS ECU (TMC Made) ABS ECU (TMC Made) A/C Evaporator Temp. Sensor A/C Amplifier A6 Blower SW A5 ABS Relay A4 * These are the page numbers of the first page on which the related system is shown. The part indicated is located somewhere in the system, not necessarily on the page indicated here. [LOCATION] (1) (7) 54 A1 A2 A3 ABS Relay CB or Fuse ABS Actuator and ECU (TMM Made) Location Code or Location ABS Actuator (TMC Made) Parts A/C Triple Pressure SW (A/C Dual and Single Pressure SW) A/C Magnetic Clutch and Lock Sensor ABS Actuator and ECU (TMM Made) A/C Condenser Fan Motor (5S–FE) *Page Nos. of Related Systems 242 126 242 246 246 214 210 214 210 210 246 252 126 210 210 246 246 126 222 152 236 166 246 246 246 220 160 220 252 252 252 252 224 252 252 166 252 252 : J/B No. 1 (See page 20 20) : R/B No. 7 (See page27 ) (2) (8) : J/B No. 2 (See page 22 19) : Fuse Box (F10, F17 See on page 28 29 ) (3) : R/B No. 1 (See page 25 23) C2 C3 C4 C5 C6 C7 (4) C8 C9 : R/B No. 4 (See page25 20) (5) C10 C11 C12 : R/B No. 5 (See page 26 19) (6) C13 C14 C16 D1 D3 Diode (for Courtesy) (W/G) Door Lock Control Relay Diode (for Courtesy) Diode (for Idle–Up) Daytime Running Light Relay (Main) (CANADA) 80 Data Link Connector 2 (TDCL (Toyota Diagnostic Communication Link)) Data Link Connector 1 (Check Connector) Cruise Control ECU Cooling Fan ECU (1MZ–FE) Combination SW Front Wiper and Washer SW) Combination SW (Light Control SW) Combination SW (Turn Signal SW) Combination SW (Horn SW) Combination Meter (SRS Warning Light) Combination Meter (A/T Indicator Light) Combination Meter Combination Meter (ABS Warning Light) Combination Meter (Meter Illmination) Combination Meter (Open Door Warning Light) Combination Meter (Seat Belt Warning Light) Combination Meter (Charge Warning Light) Combination Meter (High Beam Indicator Light) Combination Meter (Malfunction Indicator Light) Combination Meter (Rear Light Warning Light) Combination Meter Combination Meter (Cruise Control Indicator Light) Combination Meter (Turn Signal Indicator Light) Clutch Start SW (M/T) Clock Cigarette Lighter Illumination Cigarette Lighter Center Airbag Sensor Assembly Cruise Control Actuator 130 120 80 126 104 106 90 68 192 177 189 126 189 192 114 236 210 126 134 170 76 104 90 124 236 177 198 173 114 112 126 184 244 192 98 118 214 106 118 186 72 138 144 204 98 144 148 214 140 148 90 98 106 80 134 156 134 192 204 90 236 138 140 140 214 98 130 140 D4 D6 D7 D8 D9 R/B No. 6 (See Page26 ) 55 POWER SOURCE (Current Flow Chart)
40A AM1 15A CIG/RADIO 40A DEFOG 15A ECU–1G 10A GAUGE 7.5A IGN 10A MIR–HTR 30A POWER 7.5A SRS 15A STOP 15A TAIL 7.5A TURN 20A WIPER 30A AM2 7.5A ALT–S 30A CDS FAN 20A DOME 15A ECU–B 15A EFI 10A HAZ 15A HEAD (LWR–LH) 15A HEAD (LWR–RH) 15A HEAD (UPR–LH) 15A HEAD (UPR–RH) 15A HEAD LH 15A HEAD RH 10A HORN 40A MAIN 7.5A OBD 10A STARTER 10A A/C 40A HEATER 7.5A DRL 100A ALT 60A ABS Engine Control Module (Engine and Electronic Controlled Transmission ECU) (A/T) (5S–FE) Engine Control Module (Engine and Electronic Controlled Transmission ECU) (A/T) (1MZ–FE) 80 Engine Control Module (Engine and Electronic Controlled Transmission ECU) 80 Engine Controlled Transmission Pattern Select SW Electronic Controlled Transmission Solenoid Electronic Controlled Transmission Solenoid (5S–FE) Diode (for Tension Reducer) (C/P) Date Ling Connector 3 Door Lock Motor and Door Unlock Detection SW Front LH Door Lock Motor and Door Unlock Detection SW Front RH Door Lock Motor Rear LH (EX. C/P) Door Lock Motor Rear RH (EX. C/P) Door Lock Control SW RH Door Key Lck and Unlock SW LH (Ex. C/P) Door Key Lck and Unlock SW RH (Ex. C/P) Door Key Cylinder Light and SW 80 90 98 198 E5 E6 E7 E8 E9 * These are the page numbers of the first page on which the related system is shown. The part indicated is located somewhere in the system, not necessarily on the page indicated here. [LOCATION] (1) (7) 56 D12 D13 D14 D15 D16 D17 D18 D19 D20 D21 D22 D23 D24 D25 E2 E3 126 198 204 242 Engine Coolant Temp. Sensor (Water Temp. Sensor) (for Cooling Fan) (1MZ–FE) CB or Fuse 130 134 130 160 160 160 160 160 160 160 80 220 198 220 220 138 138 140 Door Courtesy SW Rear RH Location Code or Location Door Courtesy SW Rear LH Parts Door Courtesy SW Front RH Door Courtesy SW Front LH *Page Nos. of Related Systems 130 130 130 134 134 138 138 138 140 140 140 : J/B No. 1 (See page 20 20) : R/B No. 7 (See page27 ) (2) (8) : J/B No. 2 (See page 22 19) : Fuse Box (F10, F17 See on page 28 29 ) (3) : R/B No. 1 (See page 25 23) Front Side Marker LH Front Side Marker RH F3 F4 F5 F6 F7 F8 F9 F15 G2 G3 G4 (4) : R/B No. 4 (See page25 20) H1 (5) H2 H3 H4 H5 H6 H7 H8 : R/B No. 5 (See page 26 19) (6) 68 72 80 98 236 H9 H10 H11 H12 I1 72 80 Ignition Coil Injector No. 1 80 Igniter Heated Oxygen Sensor (Bank 1 Sensor 1) (1MZ–FE) Heated Oxygen Sensor (Bank 2 Sensor 1) (1MZ–FE) High Mount Stop Light 80 90 98 Idle Air Control Valve (ISC Valve) Heater Control SW (for Push Control SW Type) Air Vent Mode Control SW (for Lever Control SW Type) Heated Oxygen Sensor (Bank 1 Sensor 2) Hazard SW Horn RH Horn LH Headlight Lo RH (CANADA) Headlight Lo RH (USA) Headlight Lo LH (CANADA) Headlight Lo LH (USA) Headlight Hi RH (CANADA) Headlight Hi RH (USA) Headlight Hi LH (CANADA) Headlight Hi LH (USA) Glove Box Light SW Glove Box Light Generator (Alternator) Fuel Pump and Sender Front Wiper Motor Front turn Signal Light RH Front turn Signal Light LH Front Clearance Light RH E10 Front Clearance Light LH Engine Control Module (Engine and Electronic Controlled Transmission ECU) 80 80 90 144 144 144 144 114 114 114 98 198 148 148 148 148 118 118 184 90 76 126 126 104 106 104 106 104 106 104 106 173 173 118 126 252 80 120 80 98 124 204 126 246 236 I2 I3 I4 R/B No. 6 (See Page26 ) 57 
40A AM1 15A CIG/RADIO 40A DEFOG 15A ECU–1G 10A GAUGE 7.5A IGN 10A MIR–HTR 30A POWER 7.5A SRS 15A STOP 15A TAIL 7.5A TURN 20A WIPER 30A AM2 7.5A ALT–S 30A CDS FAN 20A DOME 15A ECU–B 15A EFI 10A HAZ 15A HEAD (LWR–LH) 15A HEAD (LWR–RH) 15A HEAD (UPR–LH) 15A HEAD (UPR–RH) 15A HEAD LH 15A HEAD RH 10A HORN 40A MAIN 7.5A OBD 10A STARTER 10A A/C 40A HEATER 7.5A DRL 100A ALT 60A ABS 90 118 134 192 224 252 98 120 138 210 I14 I16 I17 I18 I19 I20 I21 J1 J2 J3 J4 80 154 182 190 204 126 156 189 198 236 130 156 182 214 226 234 134 160 198 222 228 236 154 168 204 224 177 230 * These are the page numbers of the first page on which the related system is shown. The part indicated is located somewhere in the system, not necessarily on the page indicated here. [LOCATION] (1) (7) 58 I13 Junction Connector (for Airbag System) I11 I12 Junction Connector I9 Junction Connector Injector Key Cylinder Light I8 Junction Connector Injector No. 6 (1MZ–FE) I7 Ignition Coil No. 6 (1MZ–FE) Injector No. 5 (1MZ–FE) I6 Ignition Coil No. 5 (1MZ–FE) Injector No. 4 Location CB or Fuse 68 80 Ignition Coil No. 4 (1MZ–FE) Injector No. 3 I5 Code or Location 68 68 80 80 Ignition Coil No. 3 (1MZ–FE) Injector No. 2 Parts 68 80 76 114 130 68 80 170 214 246 Ignition Coil No. 2 (1MZ–FE) 80 130 134 68 138 80 140 Interior Light 80 Integration Relay 80 Ignition SW and Unlock Warning SW *Page Nos. of Related Systems 130 106 112 134 68 120 126 80 80 138 72 130 140 140 80 144 170 Ignition Coil No. 1 (1MZ–FE) POWER SOURCE (Current Flow Chart) : J/B No. 1 (See page 20 20) : R/B No. 7 (See page27 ) (2) (8) : J/B No. 2 (See page 22 19) : Fuse Box (F10, F17 See on page 28 29 ) (3) : R/B No. 1 (See page 25 23) Junction Connector (1MZ–FE) Key Interlock Solenoid Light Failure Sensor Luggage Compartment Light Luggage Compartment Light SW Noise Filter (for Ignition System) Noise Filter (for Stop Light) Noise Filter (for Stop Light) J5 J6 J7 K3 L1 L2 L3 L4 M2 M3 M4 M5 M6 N1 N2 N3 (4) Moon Roof Limit SW (EX. W/G) 130 134 138 140 130 168 138 168 168 168 80 : R/B No. 4 (See page25 20) (5) O1 O5 P1 P2 P3 P4 P5 P6 P7 : R/B No. 5 (See page 26 19) (6) Power Seat Motor (for Front Vertical Control) Power Seat Motor (for Rear Vertical Control) Power Seat Motor (for Slide control) Power Seat Motor (for Reclining Control) Power Window Control SW Front RH Power Window Control SW Rear LH (EX. C/P) Power Window Control SW Rear RH (EX. C/P) Power Window Master SW and Door Lock control SW LH 68 72 152 198 204 Power Seat Control SW 126 236 198 204 Parking Brake SW (for 5S–FE) 198 204 210 214 Parking Brake SW (for 1MZ–FE) 120 124 182 192 Park/Neutral Position SW (Neutral Start SW) (A/T) 198 204 210 214 O/D Main SW and A/T Indicator Light (Shift Lever) 120 124 182 192 Oil Pressure SW 80 Mass Air Flow (Air Flow Meter) (1MZ–FE) Moon Roof Motor (EX. W/G) 130 134 138 140 Moon Roof Control SW and Personal Light (w/ Moon Roof) (EX. W/G) 120 80 198 182 144 124 144 148 Moon Roof Control Relay License Plate Light Junction Connector (1MZ–FE) Junction Connector (W/G) 118 180 186 224 236 236 180 180 180 180 180 156 156 156 156 160 P8 P9 P10 P11 P12 R/B No. 6 (See Page26 ) 59 POWER SOURCE (Current Flow Chart)
40A AM1 15A CIG/RADIO 40A DEFOG 15A ECU–1G 10A GAUGE 7.5A IGN 10A MIR–HTR 30A POWER 7.5A SRS 15A STOP 15A TAIL 7.5A TURN 20A WIPER 30A AM2 7.5A ALT–S 30A CDS FAN 20A DOME 15A ECU–B 15A EFI 10A HAZ 15A HEAD (LWR–LH) 15A HEAD (LWR–RH) 15A HEAD (UPR–LH) 15A HEAD (UPR–RH) 15A HEAD LH 15A HEAD RH 10A HORN 40A MAIN 7.5A OBD 10A STARTER 10A A/C 40A HEATER 7.5A DRL 100A ALT 60A ABS R5 R6 R7 Stop Light LH [Rear Comb. Light LH] Taillight LH [Rear Comb. Light LH] Rear Turn Signal Light LH [Rear Comb. Light LH] Stop Light LH [Rear Comb. Light LH] Taillight LH [Rear Comb. Light LH] Back–up Light LH [Rear Comb. Light LH] Stop Light RH [Rear Comb. Light RH] Taillight RH [Rear Comb. Light RH] Rear Turn Signal Light RH [Rear Comb. Light RH] Taillight RH [Rear Comb. Light RH] Stop Light RH [Rear Comb. Light RH] Back–up Light RH [Rear Comb. Light RH] Rear Window Defogger (+) (EX. W/G) Rear Window Defogger (–) (EX. W/G) Rear Window Defogger (–) (W/G) Rheostat Remote Control mirror SW Rear Window Defogger SW Radio and Player (w/o CD Player) Radiator Fan Motor (5S–FE) R3 126 154 126 120 144 114 120 144 152 120 144 114 144 120 152 190 190 190 124 148 118 148 124 190 124 148 148 124 148 R8 R10 R9 R11 R16 R17 * These are the page numbers of the first page on which the related system is shown. The part indicated is located somewhere in the system, not necessarily on the page indicated here. [LOCATION] (1) (7) 60 Radio and Player (w/ CD Player) CB or Fuse Power Window Motor Rear LH (EX. C/P) Power Window Motor Rear RH (EX. C/P) Location Code or Location Power Window Motor Front RH Parts 126 222 224 228 234 P13 P14 P15 P16 R1 R2 Power Window Motor Front LH *Page Nos. of Related Systems 156 156 156 156 242 126 : J/B No. 1 (See page 20 20) : R/B No. 7 (See page27 ) (2) (8) : J/B No. 2 (See page 22 19) : Fuse Box (F10, F17 See on page 28 29 ) (3) : R/B No. 1 (See page 25 23) Stop Light SW S5 S8 S9 S10 (4) V1 V2 : R/B No. 4 (See page25 20) V5 V8 (5) : R/B No. 5 (See page 26 19) (6) 80 90 98 198 204 Headlight Relay (Coil Side) 80 90 98 198 204 EFI Main Relay (Point Side) 80 90 130 130 130 156 156 80 98 192 134 134 184 236 134 190 190 190 160 160 112 126 68 68 186 126 72 72 198 236 138 138 138 168 168 EFI Main Relay (Coil Side) Starter Relay (Coil Side) Starter Relay (Point Side) Taillight Relay (Point Side) Taillight Relay (Coil Side) Power Main Relay (Point Side) Power Main Relay (Coil Side) Defogger Relay (Point Side) Defogger Relay (Coil Side) Noise Filter Diode Water Temp. Sender Washer Motor Vanity Light RH Vanity Light LH V3 V4 Vehicle Speed Sensor (Speed Sensor) 80 90 98 VSV (for Intake Air Control) (1MZ–FE) 80 90 VSV (for Fuel Pressure Up) VSV (for EGR System) (1MZ–FE) VSV (for A/C Idle–Up) Stereo Component Amplifier Stereo Component Amplifier R18 R19 R20 R21 S3 Shift Lock ECU Starter (1MZ–FE) Remote Control Mirror RH Remote Control Mirror LH Rear Wiper Relay (W/G) Rear Wiper Motor (W/G) 120 182 80 186 186 154 154 68 182 226 226 192 198 90 72 230 230 204 210 98 214 106 V9 W1 W2 R/B No. 6 (See Page26 ) 61 POWER SOURCE (Current Flow Chart) Circuit Opening Relay (Coil Side) Daytime Running Light Relay No. 3 (Coil Side) Daytime Running Light Relay No. 4 (Coil Side) Circuit Opening Relay (Coil Side) Heater Relay (Coil Side) Radiator Fan Relay No. 2 (Coil Side) Radiator Fan Relay No. 2 (Point Side) Radiator Fan Relay No. 3 (Point Side) A/C Magnetic Clutch Relay (Coil Side) A/C Magnetic Clutch Relay (Point Side) Heater Relay (Point Side) Turn Signal Flasher Radiator Fan Relay (Coil Side) Location Horn Relay Code or Location Headlight Relay (Point Side) Parts Radiator Fan Relay (Point Side) *Page Nos. of Related Systems 80 80 173 106 242 242 114 246 246 242 242 242 246 246 90 90 106 106 118 98 98 CB or Fuse
40A AM1 15A CIG/RADIO 40A DEFOG 15A ECU–1G 10A GAUGE 7.5A IGN 10A MIR–HTR 30A POWER 7.5A SRS 15A STOP 15A TAIL 7.5A TURN 20A WIPER 30A AM2 7.5A ALT–S 30A CDS FAN 20A DOME 15A ECU–B 15A EFI 10A HAZ 15A HEAD (LWR–LH) 15A HEAD (LWR–RH) 15A HEAD (UPR–LH) 15A HEAD (UPR–RH) 15A HEAD LH 15A HEAD RH 10A HORN 40A MAIN 7.5A OBD 10A STARTER 10A A/C 40A HEATER 7.5A DRL 100A ALT 60A ABS * These are the page numbers of the first page on which the related system is shown. The part indicated is located somewhere in the system, not necessarily on the page indicated here. [LOCATION] (1) (4) (7) 62 : J/B No. 1 (See page 20 20) : R/B No. 4 (See page25 ) : R/B No. 7 (See page27 20) (2) (5) (8) : J/B No. 2 (See page 22 19) : R/B No. 5 (See page26 ) : Fuse Box (F10, F17 See on page 28 29 19) (3) (6) : R/B No. 1 (See page 25 23) : R/B No. 6 (See page 26 ) POWER SOURCE (Current Flow Chart) -Memo 37 POWER SOURCE W W 7 IP3 W W 1 1E (5S–FE) 4 EF1 W 3 EF1 W E14 : 1MZ–FE E23 : 5S–FE E14 : 1MZ–FE E15 : 5S–FE E14 : 1MZ–FE E20 : 5S–FE W W W W W 4 I2 1 1 B 3 40A AM1 G1 GENERATOR (ALTERNATOR) 40A HEATER W W 4 9 1G 4 W W TO ABS ACTUATOR 2 L W–L 1 2H 100A ALT (1MZ–FE) 60A ABS (5S–FE) 1 E 3 5 4 30A CDS FAN 2 1 6 2G ENGINE MAIN RELAY 6 2B 1 C 2 W E , F18 FUSE BOX B , F16 D A , F10 C 1 D F17 F10 30A RDI FAN 1 A (1MZ–FE) 1 B (5S–FE) 2B B–R W W–B W–B 15 3A W–R E6 7. 5A OBD (5S–FE) 16 3C 15A ECU–B 15A TEL B–R 7. 5A ALT–S 10A HORN W–B 10A HAZ 20A DOME B B 2 1 30A AM2 2H W–R 2G 15A EFI STARTER RELAY 3 5 40A MAIN B FL MAIN 2. 0L B HEADLIGHT RELAY 4 2 1 2C 2 5 2C 1 2F W 3 6 EC1 1 1 W 2E 2 15A HEAD (RH) 2E B (CANADA) BATTERY (USA) 15A HEAD (LH) 5 1 DAYTIME RUNNING LIGHT RELAY NO. 2 2 3 64 R–L 5 5 R W–B W (CANADA) 2 B–R 2 15A HEAD (UPR–RH) 2H 15A HEAD (UPR–LH) 15A STOP 7. 5A SRS W W 4 1E 5 3 1 2 15A TAIL TAILLIGHT RELAY 1 POWER MAIN RELAY 2 5 3 1 1M 30A POWER W 2 1E W 2 1 TO DOOR LOCK CONTROL RELAY 40A DEFOG 1 2 5 3 2 1 I12 IGNITION SW W W–B 10A MIR HTR 10 1C W–B DEFOGGER RELAY 4 AM1 ACC 3 P–L IG1 2 B–Y 10 1G 3 1G 15A CIG/RADIO 15A ECU–IG 20A WIPER ST1 7 B–W 10A GAUGE W–R 10 AM2 B–O IG2 9 8 1G 7. 5A TURN 7. 5A IGN ST2 7 1A B–R W–B B–R TO STARTER 10A STARTER B–R B–R 17 IP1 B–R 1 E10 : 1MZ–FE E20 : 5S–FE E6 W 4 15A HEAD (LWR–RH) E7 W 5 3 4 5 R–W 15A HEAD (LWR–LH) W W 5 1 2 5 R EB1 W 7 2 1 7 W–R EB W–B 7. 5A DRL 1 W–B W 5 IG 65 POWER SOURCE SERVICE HINTS TAILLIGHT RELAY 5–3 : CLOSED WITH LIGHT CONTROL SW AT TAIL OR HEAD POSITION CLOSED WITH ENGINE RUNNING AND PARKING BRAKE LEVER RELEASED (CANADA) ENGINE MAIN RELAY 4–5 : CLOSED WITH IGNITION SW AT ON OR ST POSITION HEADLIGHT RELAY 2–1 : CLOSED WITH LIGHT CONTROL SW AT HEAD POSITION OR DIMMER SW AT FLASH POSITION CLOSED WITH ENGINE RUNNING AND PARKING BRAKE LEVER RELEASED (CANADA) I12 IGNITION SW 4–3 : CLOSED WITH IGNITION KEY AT ACC OR ON POSITION 10–9, 4–2 : CLOSED WITH IGNITION KEY AT ON OR ST POSITION : PARTS LOCATION CODE F10 F16 A 28 SEE PAGE CODE F17 E SEE PAGE 28 (1MZ–FE), 30 (5S–FE) B 30 F18 28 (1MZ–FE), 30 (5S–FE) C 28 (1MZ–FE), 30 (5S–FE) D G1 CODE I2 SEE PAGE 33 28 (1MZ–FE), 30 (5S–FE) : RELAY BLOCKS CODE 1 4 5 7 SEE PAGE 25 25 26 27 RELAY BLOCKS (RELAY BLOCK LOCATION) R/B NO. 4 (LEFT KICK PANEL) R/B NO. 4 (RIGHT KICK PANEL) R/B NO. 5 (ENGINE COMPARTMENT LEFT) R/B NO. 7 (NEAR THE BATTERY) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1A SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1C 1E 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 22 22 22 ENGINE ROOM MAIN WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) ENGINE WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) ENGINE ROOM MAIN WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 22 COWL WIRE AND J/B NO NO. 2 (ENGINE COMPARTMENT LEFT) 22 ENGINE WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO NO. 3 (BEHIND COMBINATION METER) 1G 1M 2B 2C 2E 2F 2G 2H 3A 3C : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE EB1 EC1 EF1 IP1 IP3 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ENGINE ROOM MAIN WIRE AND RELAY WIRE ENGINE WIRE AND ENGINE ROOM MAIN WIRE 38 (1MZ–FE) 40 (5S–FE) ENGINE WIRE AND COWL WIRE 44 : GROUND POINTS CODE EB IG SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 42 GROUND POINTS LOCATION FRONT LEFT FENDER INSTRUMENT PANEL BRACE LH : SPLICE POINTS CODE E6 E7 E10 66 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) WIRE HARNESS WITH SPLICE POINTS ENGINE ROOM MAIN WIRE 40 (5S–FE) 38 (1MZ–FE) CODE E14 SEE PAGE 38 (1MZ–FE) E15 E20 40 (5S–FE) (5S FE) WIRE HARNESS WITH SPLICE POINTS ENGINE WIRE E23 ENGINE WIRE I2 44 COWL WIRE 67 STARTING AND IGNITION (1MZ–FE) B–O ACC IG1 ST1 7 B–W 4 AM1 IG2 9 B–O ST2 10 AM2 6 1G I12 IGNITION SW W–R 5 1E 9 1G 1 2G B–W B–R 1 5 1 B–W 40A MAIN 10A STARTER 5 3 4 N B STARTER RELAY B–W 2 2H W 1 1 1E 17 IP1 6 5 2 5 2C 1 2F 2 2C 2 3C B W 3 EF1 P 1 B 30A AM2 W–B 40A AM1 1 EF1 B–R 2 20 3B 2 3D 1 A B–W B–W E10 B–R W–B TO CIRCUIT OPENING RELAY 18 3C TO ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) A , F16 FUSE BOX B–R 11 1C 1 1M B 1 B F10 100A ALT B 6 3C B FL MAIN 2. 0L 1 A 1 B W–B B–R M BATTERY S3 A , S4 B STARTER IG 68 P1 PARK/NEUTRAL POSITION SW (NEUTRAL START SW) W B–W B–O 8 1G W–R 5 1E B–O IP1 B–O B–O B–O B–O B–O 1 1 2 2 2 2 2 2 A 3 A 4 A 5 A 6 A 7 A COIL1 COIL2 COIL3 COIL4 COIL5 COIL6 GND TACH P G 2 I21 IGNITON COIL NO. 6 B–O 1 I20 IGNITON COIL NO. 5 LG–B B–O 1 I19 IGNITON COIL NO. 4 1 I18 IGNITON COIL NO. 3 1 I17 IGNITON COIL NO. 2 B–O E13 B–O E13 W +B B–O E13 GR 1 A E14 B–O E12 I16 IGNITON COIL NO. 1 B–O E14 L B–O I 2 A , I15 B IGNITER IGF 7 B 8 A B 1 B G–R 2 B IGT6 R–B 3 B IGT5 L–B 4 B IGT4 GR–B 5 B IGT3 Y–R 6 B IGT2 W–G 8 B IGT1 W–R 12 24 16 15 26 30 29 19 IGF IGT1 IGT2 IGT3 IGT4 IGT5 IGT6 IG– E1 D1 DATA LINK CONNECTOR 1 (CHECK CONNECTOR) A J7 JUNCTION CONNECTOR A BR E7 ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) BR 3 W–B TO NOISE FILTER (FOR IGNITION SYSTEM) 16 EC ED 69 STARTING AND IGNITION (1MZ–FE) SERVICE HINTS I12 IGNITION SW 4–7 : CLOSED WITH IGNITION SW AT ST POSITION 10–9 : CLOSED WITH IGNITION SW AT ON OR ST POSITION STARTER RELAY (6) 2– (6) 4 : CLOSED WITH CLUTCH START SW ON AND IGNITION SW AT ST POSITION (M/T) CLOSED WITH IGNITION SW AT ST POSITION (A/T) STARTER POINTS CLOSED WITH CLUTCH START SW ON AND IGNITION SW AT ST POSITION P 1 PARK/NEUTRAL POSITION SW (NEUTRAL START SW) (A/T) 2–3 : CLOSED WITH A/T SHIFT LEVER IN P OR N POSITION : PARTS LOCATION CODE SEE PAGE D1 28 E7 CODE I15 SEE PAGE B CODE 29 SEE PAGE I21 29 33 32 I16 29 J7 F10 A 28 I17 29 P1 F16 B 28 I18 29 S3 A 29 I2 A 29 I19 29 S4 B 29 33 I20 29 I12 29 : RELAY BLOCKS CODE 1 SEE PAGE 25 RELAY BLOCKS (RELAY BLOCK LOCATION) R/B NO. 1 (LEFT KICK PANEL) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1C 1E 1G 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 1M 2C 22 ENGINE WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 2G 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 2H 22 ENGINE WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 2F 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 3C 24 COWL WIRE AND J/B NO. 3 (BEHIND COMBINATION METER) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE EF1 IP1 SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) 38 (1MZ–FE) 40 (5S–FE) ENGINE WIRE AND COWL WIRE 44 : GROUND POINTS CODE EC ED IG SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) 42 GROUND POINTS LOCATION INTAKE MANIFOLD RH INTAKE MANIFOLD LH INSTRUMENT PANEL BRACE LH : SPLICE POINTS CODE E10 E12 70 SEE PAGE 38 (1MZ–FE) (1MZ FE) WIRE HARNESS WITH SPLICE POINTS ENGINE WIRE CODE E13 E14 SEE PAGE 38 (1MZ–FE) (1MZ FE) WIRE HARNESS WITH SPLICE POINTS ENGINE WIRE 71 STARTING AND IGNITION (5S–FE) B–O ACC IG1 ST1 7 4 AM1 W W–R 10 AM2 B–W IG2 9 ST2 B–O 6 1G I12 IGNITION SW 5 1E B–W B–R 9 1G 1 2G (A/T) 1 1 EF1 3 1 1 4 STARTER RELAY 2 5 2C 1 2F 1 EF1 IP1 B–R 17 B B–W W–B 2 3D F10 A , F16 FUSE BOX B 20 3B B–W W B–R E20 TO CIRCUIT OPENING RELAY 6 3C W–B 18 3C B–R TO ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU (A/T), ENGINE ECU (M/T)) 100A ALT B B 11 1C 1 1M FL MAIN 2. 0L 1 A 1 B W–B B–R M BATTERY S3 A ,S4 B STARTER IG 72 B–W 6 2 (M/T) 1 A 1 B N 2 2C B 2 3C 3 EF1 5 5 P B B–W 1 B W 2 2H W–B 1 1E 1 B 10A STARTER (A/T) 40A MAIN (A/T) P1 PARK/NEUTRAL POSITION SW (NEUTRAL START SW) (A/T) B–W 30A AM2 C7 CLUTCH START SW (M/T) 40A AM1 (M/T) 5 (M/T) 2 * 1 : CALIFORNIA * 2 : EX. CALIFORNIA * 3 : ONE BODY ASSEMBLY EX. CALIFORNIA B–O 8 1G W–R 6 1A IP1 W–R 16 W–R W–R E20 I3 IGNITION COIL W–R TO NOISE FILER (FOR IGNITION SYSTEM) 1 (* 3) B–R W–R 2 A (* 1) , D 2 D2 B (*2) DISTRIBUTOR 5 3 C– G2 NE– 3 A (*1) (*2) 4 A 3 B (* 1) (* 2) NE G1 E7 IGT IG– 2 4 G2 NE– B ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) E19 B (SHIELDED) IP1 B B 8 3 A 13 B G– A , E11 L L 5 A 18 B (* 2, M/T) B 17 A 5 B L Y 18 A 4 B (* 1, A/T) R BR IGF 1 2 B E16 4 A +B I2 IGNITER B 2 A 4 B G– G– W–R 1 A 1 B G1 G+ W NE NE+ 3 B IGF 20 A (* 1, A/T) 22 B (* 2, M/T) IGT 19 IG– TO TACHOMETER [COMB. METER] D1 DATA LINK CONNECTOR 1 (CHECK CONNECTOR) EC 73 STARTING AND IGNITION (5S–FE) SERVICE HINTS I12 IGNITION SW 4–7 : CLOSED WITH IGNITION SW AT ST POSITION 10–9 : CLOSED WITH IGNITION SW AT ON OR ST POSITION C 7 CLUTCH START SW (M/T) 1–2 : CLOSED WITH CLUTCH PEDAL FULLY DEPRESSED STARTER RELAY (6) 2– (6) 4 : CLOSED WITH CLUTCH START SW ON AND IGNITION SW AT ST POSITION (M/T) CLOSED WITH IGNITION SW AT ST POSITION (A/T) STARTER POINTS CLOSED WITH CLUTCH START SW ON AND IGNITION SW AT ST POSITION P 1 PARK/NEUTRAL POSITION SW (NEUTRAL START SW) (A/T) 2–3 : CLOSED WITH A/T SHIFT LEVER IN P OR N POSITION : PARTS LOCATION CODE SEE PAGE C7 D1 D2 E7 CODE SEE PAGE 32 E11 B 32 CODE SEE PAGE I12 33 30 F10 A 30 A 30 F16 B 30 S3 P1 A 31 31 B 30 I2 31 S4 B 31 A 32 I3 31 : RELAY BLOCKS CODE 1 SEE PAGE 25 RELAY BLOCKS (RELAY BLOCK LOCATION) R/B NO. 1 (LEFT KICK PANEL) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1A 1C 1E 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 22 ENGINE WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 22 COWL WIRE AND J/B NO NO. 2 (ENGINE COMPARTMENT LEFT) 22 ENGINE WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO. 3 (BEHIND COMBINATION METER) 1G 1M 2C 2F 2G 2H 3B 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE EF1 IP1 SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) 38 (1MZ–FE) 40 (5S–FE) ENGINE WIRE AND COWL WIRE 44 : GROUND POINTS CODE EC IG SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 42 GROUND POINTS LOCATION INTAKE MANIFOLD RH INSTRUMENT PANEL BRACE LH : SPLICE POINTS CODE E16 E19 74 SEE PAGE 40 (5S–FE) (5S FE) WIRE HARNESS WITH SPLICE POINTS ENGINE WIRE CODE E20 SEE PAGE 40 (5S–FE) WIRE HARNESS WITH SPLICE POINTS ENGINE WIRE 75 CHARGING W FROM POWER SOURCE SYSTEM (SEE PA GE 64) 10A GAUGE 7. 5A IGN 3 1D 6 2C F10 A , F10 B , F16 8 C W FROM DAYTIME RUNNING LIGHT RELAY (MAIN) (5S–FE) 9 Y 1 B 100A ALT 1 A (1MZ–FE) C9 CHARGE WARNING LIGHT [COMB. METER] W R–L B–O 6 1D 7. 5A ALT–S FUSE BOX E J1 JUNCTION CONNECTOR 1 C E Y (CANADA) B Y E FL MAIN 2. 0L IP3 10 R–L 2 IP3 Y W R–L I18 R–L G1 A 2 B 1 B 3 B IG BATTERY L S TO BACK–UP SW (M/T) TO PARK/NEUTRAL POSITION SW (NEUTRAL START SW) (A/T) TO VEHICLE SPEED SENSOR (SPEED SENSOR) IC REGULATOR 76 1 A B , G2 B GENERATOR (ALTERNATOR) SERVICE HINTS G 1(B) GENERATOR (ALTERNATOR) (B) 3–GROUND : 13.9–15.1 VOLTS WITH ENGINE RUNNING AT 2000 RPM AND 25°C (77°F) 13.5–14.3 VOLTS WITH ENGINE RUNNING AT 2000 RPM AND 115°C (239°F) (B) 1–GROUND : 0–4 VOLTS WITH IGNITION SW AT ON POSITION AND ENGINE NOT RUNNING : PARTS LOCATION CODE SEE PAGE C9 F10 CODE SEE PAGE 32 F16 C 28 (1MZ–FE), 30 (5S–FE) A 28 (1MZ–FE), 30 (5S–FE) G1 A 28 (1MZ–FE), 30 (5S–FE) B 28 (1MZ–FE), 30 (5S–FE) G2 B 28 (1MZ–FE), 30 (5S–FE) CODE SEE PAGE J1 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1D 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 2C 22 ENGINE WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE IP3 SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) 44 ENGINE WIRE AND COWL WIRE : SPLICE POINTS CODE I18 SEE PAGE WIRE HARNESS WITH SPLICE POINTS ENGINE WIRE 44 (1M–FE) C9 CODE F10 SEE PAGE (5S–FE) A WIRE HARNESS WITH SPLICE POINTS F10 B F16 1 X X 8 G1 A C 1 9 G2 B BLACK J1 DARK GRAY 1 E 1 2 E E 3 (HINT : SEE PAGE 7) 77 ENGINE CONTROL (1MZ–FE) SYSTEM OUTLINE THIS SYSTEM UTILIZES AN ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) AND MAINTAINS OVERALL CONTROL OF THE ENGINE, TRANSMISSION AND SO ON. AN OUTLINE OF THE ENGINE CONTROL IS EXPLAINED HERE. 1. INPUT SIGNALS (1) ENGINE COOLANT TEMP. (WATER TEMP.) SIGNAL CIRCUIT THE ENGINE COOLANT TEMP. SENSOR (WATER TEMP. SENSOR) DETECTS THE ENGINE COOLANT TEMP. AND HAS A BUILT–IN THERMISTOR WITH A RESISTANCE WHICH VARIES ACCORDING TO THE WATER TEMP. IS INPUT INTO TERMINAL THW OF ENGINE CONTROL MODULE (ECU) AS A CONTROL SIGNAL. (2) INTAKE AIR TEMP. SIGNAL CIRCUIT THE INTAKE AIR TEMP. SENSOR IS INSTALLED IN THE MASS AIR FLOW (AIR FLOW METER) AND DETECTS THE INTAKE AIR TEMP., WHICH IS INPUT AS A CONTROL SIGNAL TO TERMINAL THA OF ENGINE CONTROL MODULE (ECU). (3) OXYGEN SENSOR SIGNAL SYSTEM THE OXYGEN DENSITY IN THE EXHAUST GASES IS DETECTED AND INPUT AS A CONTROL SIGNAL TO TERMINAL OXL, OXR AND OXS OF THE ENGINE CONTROL MODULE (ECU). TO MAINTAIN STABLE DETECTION PERFORMANCE BY THE OXYGEN SENSOR, A HEATER IS USED FOR WARMING THE SENSOR. THE HEATER IS ALSO CONTROLLED BY THE ENGINE CONTROL MODULE (ECU) (HTL, HTR AND HTS). (4) RPM SIGNAL SYSTEM CAMSHAFT POSITION AND CRANKSHAFT POSITION ARE DETECTED BY THE CAMSHAFT POSITION SENSOR AND CRANKSHAFT POSITION SENSOR. CRANKSHAFT POSITION IS INPUT AS A CONTROL SIGNAL TO TERMINAL G22+ OF THE ENGINE CONTROL MODULE (ECU), AND ENGINE RPM IS INPUT TO TERMINAL NE+. (5) THROTTLE SIGNAL CIRCUIT THE THROTTLE POSITION SENSOR DETECTS THE THROTTLE VALVE OPENING ANGLE AS A CONTROL SIGNAL, WHICH IS INPUT INTO TERMINAL VTA OF THE ENGINE CONTROL MODULE (ECU). WHEN THE VALVE IS COMPLETELY CLOSED, THE CONTROL SIGNAL IS INPUT INTO TERMINAL IDL. (6) VEHICLE SPEED SIGNAL SYSTEM THE VEHICLE SPEED SENSOR (SPEED SENSOR), INSTALLED INSIDE THE COMBINATION METER, DETECTS THE VEHICLE SPEED AND INPUTS A CONTROL SIGNAL TO TERMINAL SP1 OF THE ENGINE CONTROL MODULE (ECU). (7) PARK/NEUTRAL POSITION SW (NEUTRAL START SW) SIGNAL SYSTEM THE PARK/NEUTRAL POSITION SW (NEUTRAL START SW) DETECTS WHETHER THE SHIFT POSITION IS IN NEUTRAL OR PARKING OR NOT, AND INPUTS A CONTROL SIGNAL TO TERMINAL NSW OF THE ENGINE CONTROL MODULE (ECU). (8) A/C SW SIGNAL SYSTEM THE A/C AMPLIFIER INPUTS THE A/C OPERATIONS TO TEMRINAL A/C OF THE ENGINE CONTROL MODULE (ECU) AS A CONTROL SIGNAL. (9) BATTERY SIGNAL CIRCUIT VOLTAGE IS CONSTANTLY APPLIED TO TERMINAL BATT OF THE ENGINE CONTROL MODULE (ECU). WHEN THE IGNITION SW TURNED ON, VOLTAGE FOR ENGINE CONTROL MODULE (ECU) START–UP POWER SUPPLY IS APPLIED TO TERMINALS +B AND +B1 OF ENGINE CONTROL MODULE (ECU) VIA EFI MAIN RELAY. (10) INTAKE AIR VOLUME SIGNAL CIRCUIT INTAKE AIR VOLUME IS DETECTED BY THE MASS AIR FLOW (AIR FLOW METER) AND THE SIGNAL IS INPUT TO TERMINAL VG OF THE ENGINE CONTROL MODULE (ECU). AS A CONTROL SIGNAL. (11) STA SIGNAL CIRCUIT TO CONFIRM WHETHER THE ENGINE IS CRANKING, THE VOLTAGE APPLIED TO THE STARTER MOTOR DURING CRANKING IS DETECTED AND THE SIGNAL IS INPUT INTO TERMINAL STA OF THE ENGINE CONTROL MODULE (ECU) AS A CONTROL SIGNAL. (12) ENGINE KNOCK SIGNAL CIRCUIT ENGINE KNOCKING IS DETECTED BY THE KNOCK SENSOR NO. 1 AND NO. 2 AND THE SIGNALS ARE INPUT INTO TERMINALS KNKR AND KNKL AS A CONTROL SIGNAL. 78 2. CONTROL SYSTEM * SFI (SEQUENTIAL MULTIPORT FUEL INJECTION) (EFI (ELECTRONIC FUEL INJECTION) SYSTEM THE EFI SYSTEM MONITORS THE ENGINE CONDITION THROUGH THE SIGNALS INPUT FROM EACH SENSOR (INPUT SIGNALS FROM (1) TO (12) ETC.). THE BEST FUEL INJECTION VOLUME IS DECIDED BASED ON THIS DATA AND THE PROGRAM MEMORIZED BY THE ENGINE CONTROL MODULE (ECU), AND THE CONTROL SIGNAL IS OUTPUT TO TERMINALS #10, #20, #30, #40, #50 AND #60 OF THE ENGINE CONTROL MODULE (ECU) TO OPERATE THE INJECTOR (INJECT THE FUEL). THE EFI SYSTEM PRODUCES CONTROL OF FUEL INJECTION OPERATION BY THE ENGINE CONTROL MODULE (ECU) IN RESPONSE TO THE DRIVING CONDITIONS. * ESA (ELECTRONIC SPARK ADVANCE) SYSTEM THE ESA SYSTEM MONITORS THE ENGINE CONDITION THROUGH THE SIGNALS INPUT TO THE ENGINE CONTROL MODULE (ECU) FROM EACH SENSOR (INPUT SIGNALS FROM (1), (3), (4) TO (12) ETC.). THE BEST IGNITION TIMING IS DECIDED ACCORDING TO THIS DATA AND THE MEMORIZED DATA IN THE ENGINE CONTROL MODULE (ECU) AND THE CONTROL SIGNAL IS OUTPUTS TO TERMINALS IGT1, IGT2, IGT3, IGT4, IGT5 AND IGT6. THIS SIGNAL CONTROLS THE IGNITER TO PROVIDE THE BEST IGNITION TIMING FOR THE DRIVING CONDITIONS. * HEATED OXYGEN SENSOR (OXYGEN SENSOR) HEATER CONTROL SYSTEM THE OXYGEN SENSOR HEATER CONTROL SYSTEM TURNS THE HEATER ON WHEN THE INTAKE AIR VOLUME IS LOW (TEMP. OF EXHAUST EMISSIONS IS LOW), AND WARMS UP THE OXYGEN SENSOR (NO. 1 AND NO. 2) TO IMPROVE DETECTION PERFORMANCE OF THE SENSOR. THE ENGINE CONTROL MODULE (ECU) EVALUATES THE SIGNALS FROM EACH SENSOR (INPUT SIGNALS FROM (1), (4), (9) TO (10) ETC.), AND OUTPUT CURRENT TO TERMINALS HTL, HTR AND HTS AND CONTROL THE HEATER. * IAC (IDLE AIR CONTROL (ISC)) SYSTEM THE IAC (ISC) SYSTEM (ROTARY SOLENOID TYPE) INCREASES THE RPM AND PROVIDES IDLE STABILITY FOR FAST IDLE–UP WHEN THE ENGINE IS COLD, AND WHEN THE IDLE SPEED HAS DROPPED DUE TO ELECTRICAL LOAD AND SO ON, THE ENGINE CONTROL MODULE (ECU) EVALUATES THE SIGNALS FROM EACH SENSOR (INPUT SIGNALS FROM (1), (4), (5), (8), (9) ETC.), OUTPUTS CURRENT TO TERMINALS RSO AND RSC TO CONTROL IDLE AIR CONTROL VALVE. * EGR CONTROL SYSTEM THE EGR CONTROL SYSTEM DETECTS THE SIGNAL FROM EACH SENSOR (INPUT SIGNALS FROM (1), (4), (9), (10), ETC)., AND OUTPUTS CURRENT TO TERMINAL EGR TO CONTROL THE EGR VALVE. * ACIS (ACOUSTIC CONTROL INDUCTION SYSTEM) ACIS INCLUDES A VALVE IN THE BULKHEAD SEPARATING THE SURGE TANK INTO TWO PARTS. THIS VALVE IS OPENED AND CLOSED IN ACCORDANCE WITH THE DRIVING CONDITIONS TO CONTROL THE INTAKE MANIFOLD LENGTH IN TWO STAGES FOR INCREASED ENGINE OUTPUT IN ALL RANGES FROM LOW TO HIGH SPEEDS. THE ENGINE CONTROL MODULE (ECU) JUDGES THE ENGINE SPEED BY THE SIGNALS ((4), (5)) FROM EACH SENSOR AND OUTPUTS SIGNALS TO THE TERMINAL ACIS TO CONTROL THE VSV (FOR OPENING AND CLOSING THE INTAKE CONTROL VALVE) 3. DIAGNOSIS SYSTEM WITH THE DIAGNOSIS SYSTEM, WHEN THERE IS A MALFUNCTION IN THE ENGINE CONTROL MODULE (ECU) SIGNAL SYSTEM, THE MALFUNCTIONING SYSTEM IS RECORDED IN THE MEMORY. 4. FAIL–SAFE SYSTEM WHEN A MALFUNCTION HAS OCCURRED IN ANY SYSTEM, IF THERE IS A POSSIBILITY OF ENGINE TROUBLE BEING CAUSED BY CONTINUED CONTROL BASED ON THE SIGNALS FROM THAT SYSTEM, THE FAIL–SAFE SYSTEM EITHER CONTROLS THE SYSTEM BY USING DATA (STANDARD VALUES) RECORDED IN THE ENGINE CONTROL MODULE (ECU) MEMORY OR ELSE STOPS THE ENGINE. 79 ENGINE CONTROL (1MZ–FE) B–O B–W 4 AM1 B–W ST1 7 B–W L–B B–O B–O W–R 9 1G 1 2G IG2 9 B–O 8 1G I12 IGNITION SW FROM POWER SOURCE SYSTEM (SEE PAGE 64) 9 1D B–O W 10 AM2 10A STARTER 7. 5A IGN 2 4 16 1 30A AM2 B–W B–W B–O 6 1A B–O 40A AM1 IP1 20 3B 2 3C 1 I20 6 9 2 B–O 15 B–O E12 B–O 6 I18 4 6 B–O B–O B–O B–O B–O B–O W–B I18 1 6 6 13 3A IJ1 L–B 18 3C W–B 2 4 BX1 11 1C L–B 1 1 1M G–R W–B Y 1 I5 INJECTOR NO. 2 I8 INJECTOR NO. 5 1 2 R 2 L 1 I7 INJECTOR NO. 4 I6 INJECTOR NO. 3 1 2 GR I9 INJECTOR NO. 6 1 W FL MAIN 2. 0L 2 G B I4 INJECTOR NO. 1 B 16 2 L–B B–O B A , F16 FUSE BOX F10 B–O L–B I18 E12 IP3 CIRCUIT OPENING RELAY G–R W 100A ALT 6 3 1 B B–O IP1 3 EF1 1 A 4 IP1 B–W B–O B W B–O 2 3D L–B 2 2H 1 1E Y R L BATTERY GR G W IG 80 B–O B–O B–W B–W L–B L–B B–O B–O A A B–O J6 JUNCTION CONNECTOR IP1 P 2 1 18 IP3 ELS B–L B–R 14 A 13 A 23 A 22 A 1 C 12 C 25 A NSW STA RSO A , E8 RSC B ,E9 ACV C , E10 B–O 11 B–O IP1 6 C FPU ACIS D 7 A 8 A 5 A 10 A L GR G W # 10 6 A R # 60 9 A Y # 30 22 D B–O # 40 23 D B–O ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) +B +B1 # 20 # 50 B–O EGR R–Y W–L B–R 21 D Y–B W–L 14 D D6 DIODE (FOR IDLE–UP) E7 B–O 2 IP3 BATT L–B 2 1 EF1 2 I23 2 G–B 12 3 1 3 W–G 4 2D B–O W–B B–O I18 B–W 3 2C B–O 1 1 B–W 2 2B 5 1E 5 3C B–W 5 G 2 1 B–W B–O EFI MAIN RELAY 5 3D 1 V4 VSV (FOR INTAKE AIR CONTROL) B–O 6 1G E11 V3 VSV (FOR FUEL PRESSURE UP) B–O 3 V1 VSV (FOR A/C IDLE–UP) G 2 1 B–O E12 B–O 10 1A B–O E10 V2 VSV (FOR EGR) B–O 2 2D 14 1D B–O I18 B–O 10A MIR– HTR 15A TAIL 15A EFI I1 ILDE AIR CONTROL VALVE (ISC VALVE) B–O 18 B–O B–W FROM POWER SOURCE SYSTEM (SEE PAGE 64) B–O A I23 F15 FUEL PUMP L–B 4 M 5 W–B 5 BX1 B–O 20 G–R G–R IP1 Y R L GR G EB W–B W–B W BL 81 ENGINE CONTROL (1MZ–FE) B–O B–O B W–B B–O B–O B–O E13 B–O E14 B–O E14 L–B L–B B–O 15 A 26 A 30 A 29 A IGT2 IGT3 IGT4 IGT5 E7 BR 25 D OXS B ,E9 C , E10 B–O I18 11 C 19 B OXR R–L HTR W–B 10 C OXL HTL D ENGINE CONTROL MODULE(ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) THW THA T1 THROTTLE POSITION SENSOR E2 4 BR M6 MASS AIR FLOW (AIR FLOW METER) I18 BR E01 E02 34 A 15 B W 3 EE1 1 EE1 W–B 2 1 1 I18 BR I18 ED 82 KNKR E03 28 A G–B 33 A W VG– 1 A/C 20 D BR 3 BR VG 5 ACT 5 D BR +B 2 2 E4 ENGINE COOLANT TEMP. SENSOR (EFI WATER TEMP. SENSOR) FROM COOLING FAN ECU G–R 1 G–Y 2 B–O E1 EGR GAS TEMP. SENSOR 3 L B–Y 4 I18 L–W L–R BR L–B R–B R G–R L–W 20 B (SHIELDED) THG 14 C (SHIELDED) IDL 32 A K1 KNOCK SENSOR 1 VTA 7 B W–B VC W–B E2 22 B 1 B FROM A/C AMPLIFIER THA 21 B B–Y VG– LG–R VG 8 B 7 C TO A/C AMPLIFIER FC 18 B B–O (SHIELDED) (SHIELDED) W–B BR H12 HEATED OXYGEN SENSOR (BANK2 SENSOR1) B–O BR L–B R–L 13 B HTS V–R II1 1 R–L 8 I18 26 D IGT6 A ,E8 II1 HT 3 R–L 16 A IGT1 10 OX HT 1 L–B 24 A IGF II1 P–B 12 A 9 E R–L B G–R 1 A R–B 2 A L–B 3 A IGT6 GR–B 4 A IGT5 Y–R 5 A IGT4 W–G 6 A IGT3 W–R 8 A IGT2 (SHIELDED) IGT1 OX 3 4 +B W IGNITER H11 HEATED OXYGEN SENSOR (BANK1 SENSOR1) W B–O GND TACH 2 E (SHIELDED) COIL6 1 4 +B HT 3 P–B 7 B 8 B 7 A COIL4 COIL5 2 E B 5 B 6 B COIL3 (SHIELDED) 4 B COIL2 W 3 B IGF 4 OX COIL1 (SHIELDED) IQ1 +B 2 B BR BR H9 HEATED OXYGEN SENSOR (BANK1 SENSOR2) B–O I20 IGNITION COIL NO. 5 P LG–B 2 5 2 1 B I 2 A , I 15 B B–O W–B I21 IGNITION COIL NO. 6 2 L–B 2 B B–O B–O B–O I18 IGNITION COIL NO. 3 G I16 IGNITION COIL NO. 1 GR 1 2 4 IQ1 B–O 2 BR 1 I19 IGNITION COIL NO. 4 1 2 B–O I18 BR 1 I17 IGNITION COIL NO. 2 1 1 B–O I18 E13 B–O B–O E13 B–O B–O E12 +B B–O I18 1 (SHIELDED) W–B 8 5 1C 1M BR BR BR BR BR BR BR BR BR FROM POWER SOURCE SYSTEM (SEE PAGE 64) J7 JUNCTION CONNECTOR A (SHIELDED) A B (SHIELDED) A G I18 22 3D A A A A A IP2 14 G R 12 16 W–B IP3 SPEED BR 4 BR I18 (SHIELDED) (SHIELDED) E14 V–Y BR (SHIELDED) L B–W (SHIELDED) W (SHIELDED) BR IP2 5 BR A 3 A A 10 3D BR BR R–L 11 I18 4 EE1 2 EE1 R–L 2 BR SP1 12 D (SHIELDED) BR R L E1 16 C W–B 5 B 6 B 17 B 2 V–Y NE+ NE– BR 16 B B–W 14 B G22– G G22+ BR D ENGINE CONTROL MODULE(ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) KNKL BR C , E10 BR B ,E9 1 1 W SDL V5 VEHICLE SPEED SENSOR (SPEED SENSOR) LG A , E8 3 C 28 D TE2 E7 C G 11 D TE1 BR IP1 B–O W–B 5 C R–L G–R 19 IP3 V–Y IM1 G–R B–O 6 A R–L W G–W 2 2 C P IP1 12 3D 6 1B B 1 R–L 2 6 1D J2 JUNCTION CONNECTOR SDL B BATT 16 10A GAUGE G–B 3 3D 15 G–W A , C10 B R–L 4 3 B MALFUNCTION INDICATOR LAMP (CHECK ENGINE WARNING LIGHT) [COMB. METER] 2 18 3D E1 C9 8 3 5 SG CG D24 DATA LINK CONNECTOR 3 OX2 3 3D C8 COMBINATION METER TE2 OX1 4 BR BR TE1 GR–B D1 DATA LINK CONNECTOR 1 (CHECK CONNECTOR) 7 3D G–R 7. 5A OBD E1 I23 (SHIELDED) L–B 3 FP BR D3 DATA LINK CONNECTOR 2 (TDCL) B–O 1 +B W–B B 12 IG– F J1 JUNCTION CONNECTOR (SHIELDED) FROM POWER SOURCE SYSTEM F (SEE PAGE 64) N1 NOISE FILTER (FOR IGNITION SYSTEM) B–O 19 W–B W–B L–B (SHIELDED) (SHIELDED) (SHIELDED) B BR BR W–B BR C17 CAMSHAFT POSITION SENSOR K2 KNOCK SENSOR 2 2 1 W–B 1 1 C18 CRANKSHAFT POSITION SENSOR BR BR 2 EC ED IE 83 ENGINE CONTROL (1MZ–FE) SERVICE HINTS CIRCUIT OPENING RELAY 2–1 : CLOSED WITH STARTER RUNNING OR MEASURING PLATE (VOLUME AIR FLOW (AIR FLOW METER)) OPEN EFI MAIN RELAY 2–4 : CLOSED WITH IGNITION SW AT ON OR ST POSITION E 4 ENGINE COOLANT TEMP. SENSOR (EFI WATER TEMP. SENSOR) 1–2 : 10.0 – 20.0 K (–20°C, –4°F) : 4.0 – 7.0 K (0°C, 32°F) : 2.0 – 3.0 K (20°C, 68°F) : 0.9 – 1.3 K (40°C, 104°F) : 0.4 – 0.7 K (60°C, 140°F) : 0.2 – 0.4 K (80°C, 176°F) E 7(A), E 8(B), E 9(C), E10(D) ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) VOLTAGE AT ENGINE CONTROL MODULE (ECU) WIRING CONNECTOR BATT – E1 : ALWAYS 9.0–14.0 VOLTS +B – E1 : 9.0–14.0 VOLTS (IGNITION SW AT ON POSITION) +B1 – E1 : 9.0–14.0 VOLTS (IGNITION SW AT ON POSITION) IDL – E1 : 9.0–14.0 VOLTS (IGNITION SW ON AND THROTTLE VALVE FULLY OPEN) 0–3.0 VOLTS (IGNITION SW ON AND THROTTLE VALVE FULLY CLOSED) VC – E1 : ALWAYS 4.5–5.5 VOLTS (IGNITION SW AT ON POSITION) VTA – E1 : 0.3–0.8 VOLTS (IGNITION SW ON AND THROTTLE VALVE FULLY CLOSED) 3.2–4.9 VOLTS (IGNITION SW ON AND THROTTLE VALVE FULLY OPEN) VG – E1 : 4.0–5.5 VOLTS (IGNITION SW AT ON POSITION) THA – E1 : 0.5–3.4 VOLTS (IGNITION SW ON AND INTAKE AIR TEMP. 20°C, 68°F) THW – E1 : 0.2–1.0 VOLTS (ENGINE IDLING AND COOLANT TEMP. 80°C, 176°F) #10, #20, #30, #40, #50, #60 – E01 : 9.0–14.0 VOLTS (IGNITION SW AT ON POSITION) PULSE GENERATION (ENGINE IDLING) IGT1, IGT2, IGT3 IGT4, IGT5, IGT6 – E1 : PULSE GENERATION (ENGINE IDLING) IGF – E1 : 4.5–5.5 VOLTS (IGNITION SW AT ON POSITION) PULSE GENERATION (ENGINE IDLING) G22+ – G– : PULSE GENERATION (ENGINE IDLING) NE+ – G– : PULSE GENERATION (ENGINE IDLING) RSC, RSO – E1 : PULSE GENERATION (ENGINE IDLING AND A/C OPERATION) OXS, OXL, OXR – E1 : PULSE GENERATION (MAINTAIN ENGINE SPEED AT 2500 RPM FOR TWO MINUTES AFTER WARMING UP) HTS, HTL, HTR – E01 : 9.0–14.0 VOLTS (IGNITION SW AT ON POSITION) 0–3.0 VOLTS (ENGINE IDLING) KNKL, KNLR – E1 : PULSE GENERATION (ENGINE IDLING) NSW – E1 : 9.0–14.0 VOLTS (IGNITION SW ON AND OTHER SHIFT POSITION IN P OR N POSITION) BELOW 3.0 VOLTS (IGNITION SW ON AND SHIFT POSITION IN P OR N POSITION) SP1 – E1 : PULSE GENERATION (IGNITION SW ON AND ROTATE DRIVING WHEEL SLOWLY) TE1 – E1 : 9.0–14.0 VOLTS (IGNITION SW AT ON POSITION) TE2 – E1 : 9.0–14.0 VOLTS (IGNITION SW AT ON POSITION) W – E1 : BELOW 3.0 VOLTS (MULFUNCTION INDICATOR LAMP ON) 9.0–14.0 VOLTS (MULFUNCTION INDICATOR LAMP OFF AND ENGINE RUNNING) A/C – E1 : BELOW 1.5 VOLTS (ENGINE IDLING AND A/C SW ON) 7.5–14.0 VOLTS (A/C SW OFF) ACT – E1 : 9.0–14.0 VOLTS (ENGINE IDLING AND A/C SW ON) BELOW 1.5 VOLTS (A/C SW OFF) ACIS – E01 : 9.0–14.0 VOLTS (IGNITION SW AT ON POSITION) STA – E1 : 6.0 VOLTS OR MORE (ENGINE CRANKING) I 4, I 5, I 6, I 7, I 8, I 9 INJECTOR 1–2 : APPROX. 13.8  T 1 THROTTLE POSITION SENSOR 3–1 : 0.2–5.7 K WITH CLEARANCE BETWEEN LEVER AND STOP SCREW 0 MM (0 IN.) 2–1 : LESS THAN 2.3 K WITH CLEARANCE BETWEEN LEVER AND STOP SCREW 0.5 MM (0.020 IN.) WITH CLEARANCE BETWEEN LEVER AND STOP SCREW 0.7 MM (0.0276 IN.) 3–1 : 2.0–10.2 K WITH THROTTLE VALVE FULLY OPEN 84 : PARTS LOCATION CODE SEE PAGE C8 CODE 32 F16 H9 SEE PAGE CODE SEE PAGE B 28 I20 29 D C9 A 32 33 I21 29 C10 B 32 H11 28 J1 33 C17 28 H12 28 J2 33 C18 28 I1 29 J6 39 D1 28 29 J7 33 D3 32 I4 28 K1 29 D6 32 I5 29 K2 29 D24 32 I6 29 M6 29 E1 28 I7 29 N1 29 E4 28 I8 29 T1 29 I9 29 V1 29 29 V2 29 I2 A E7 A 32 E8 B 32 E9 C 32 I16 29 V3 29 E10 D 32 I17 29 V4 29 F10 A 28 I18 29 V5 29 30 I19 29 F15 F15 B : RELAY BLOCKS CODE SEE PAGE RELAY BLOCKS (RELAY BLOCK LOCATION) 1 25 R/B NO. 1 (LEFT KICK PANEL) 6 26 R/B NO. 6 (BEHIND GLOVE BOX) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1A 1B 1C 1D 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 22 ENGINE ROOM MAIN WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 22 ENGINE WIRE AND J/B NO NO. 2 (ENGINE COMPARTMENT LEFT) 2G 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 2H 22 ENGINE WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO NO. 3 (BEHIND COMBINATION METER) 1E 1G 1M 2B 2C 2D 3A 3B 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) EE1 40 (1MZ–FE) ENGINE WIRE AND SENSOR WIRE EF1 38 (1MZ–FE) ENGINE WIRE AND COWL WIRE II1 42 COWL WIRE AND INSTRUMENT PANEL WIRE IJ1 42 FLOOR NO. 1 WIRE AND COWL WIRE IM1 42 INSTRUMENT PANEL WIRE AND CONSOLE BOX WIRE 44 ENGINE WIRE AND COWL WIRE 44 ENGINE WIRE AND INSTRUMENT PANEL WIRE IP1 IP2 IP3 IQ1 46 (S/D) BX1 48 (C/P) FUEL GAUGE WIRE AND FLOOR NO. 1 WIRE 50 (W/G) 85 ENGINE CONTROL (1MZ–FE) : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION EB 38 (1MZ–FE) FRONT LEFT FENDER EC 38 (1MZ–FE) INTAKE MANIFOLD RH ED 38 (1MZ–FE) INTAKE MANIFOLD LH IE 42 LEFT KICK PANEL IG 42 INSTRUMENT PANEL BRACE LH 46 (S/D) BL 48 (C/P) UNDER THE LEFT QUARTER PILLAR 50 (W/G) : SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS E10 E11 E12 E13 86 38 (1MZ–FE) (1MZ FE) ENGINE WIRE CODE SEE PAGE E14 38 (1MZ–FE) I18 44 I20 I23 44 WIRE HARNESS WITH SPLICE POINTS ENGINE WIRE COWL WIRE 87 ENGINE CONTROL (5S–FE) SYSTEM OUTLINE THIS SYSTEM UTILIZES AN ENGINE CONTROL MODULE (ENGINE ECU (M/T), ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU (A/T)) AND MAINTAINS OVERALL CONTROL OF THE ENGINE, TRANSMISSION AND SO ON. AN OUTLINE OF THE ENGINE CONTROL IS EXPLAINED HERE. 1. INPUT SIGNALS (1) ENGINE COOLANT TEMP. (WATER TEMP.) SIGNAL SYSTEM THE ENGINE COOLANT TEMP. SENSOR (EFI WATER TEMP. SENSOR) DETECTS THE ENGINE COOLANT TEMP. AND HAS A BUILT–IN THERMISTOR WITH A RESISTANCE WHICH VARIES ACCORDING TO THE ENGINE COOLANT TEMP. (WATER TEMP.) THUS THE ENGINE COOLANT TEMP. (WATER TEMP.) IS INPUT IN THE FORM OF A CONTROL SIGNAL TO TERMINAL THW OF THE ENGINE CONTROL MODULE (ECU). (2) INTAKE AIR TEMP. SIGNAL SYSTEM THE INTAKE AIR TEMP. SENSOR (IN–AIR TEMP. SENSOR) IS DETECTS THE INTAKE AIR TEMP., WHICH IS INPUT AS A CONTROL SIGNAL TO TERMINAL THA OF THE ENGINE CONTROL MODULE (ECU). (3) OXYGEN SENSOR SIGNAL SYSTEM THE OXYGEN DENSITY IN THE EXHAUST GASES IS DETECTED AND INPUT AS A CONTROL SIGNAL TO TERMINAL OX1 AND OX2 OF THE ENGINE CONTROL MODULE (ECU). (4) RPM SIGNAL SYSTEM CRANKSHAFT POSITION AND ENGINE RPM ARE DETECTED BY THE PICK–UP COIL INSTALLED INSIDE THE DISTRIBUTOR. CRANKSHAFT POSITION IS INPUT AS A CONTROL SIGNAL TO TERMINALS G+ AND G2 (CALIFORNIA), OF THE ENGINE CONTROL MODULE (ECU), AND RPM IS INPUT TO TERMINAL NE+. (5) THROTTLE SIGNAL SYSTEM THE THROTTLE POSITION SENSOR DETECTS THE THROTTLE VALVE OPENING ANGLE, WHICH IS INPUT AS A CONTROL SIGNAL TO TERMINAL VTA OF THE ENGINE CONTROL MODULE (ECU), OR WHEN THE VALVE IS FULLY CLOSED, TO TERMINAL IDL (6) VEHICLE SPEED SIGNAL SYSTEM THE VEHICLE SPEED SENSOR (SPEED SENSOR), INSTALLED INSIDE THE COMBINATION METER, DETECTS THE VEHICLE SPEED AND INPUTS A CONTROL SIGNAL TO TERMINAL SPD OF THE ENGINE CONTROL MODULE (ECU). (7) PARK/NEUTRAL POSITION SW (NEUTRAL START SW) SIGNAL SYSTEM (A/T) THE PARK/NEUTRAL POSITION SW (NEUTRAL START SW) DETECTS WHETHER THE SHIFT POSITION ARE IN NEUTRAL AND PARKING OR NOT, AND INPUTS A CONTROL SIGNAL TO TERMINAL NSW OF THE ENGINE CONTROL MODULE (ECU). (8) A/C SW SIGNAL SYSTEM THE A/C AMPLIFIER INPUTS THE A/C OPERATIONS TO TARMINAL ACA OF THE ENGINE CONTROL MODULE (ECU) AS A CONTROL SIGNAL. (9) BATTERY SIGNAL CIRCUIT VOLTAGE IS CONSTANTLY APPLIED TO TERMINAL BATT OF THE ENGINE CONTROL MODULE (ECU). WHEN THE IGNITION SW TURNED ON, THE VOLTAGE FOR ENGINE CONTROL MODULE (ECU) START–UP POWER SUPPLY IS APPLIED TO TERMINALS +B AND +B1 OF ENGINE CONTROL MODULE (ECU) VIA EFI MAIN RELAY. THE CURRENT FLOWING THROUGH THE IGN FUSE FLOWS TO TERMINAL IGSW OF THE ENGINE CONTROL MODULE (ECU). (10) INTAKE AIR VOLUME SIGNAL SYSTEM INTAKE AIR VOLUME IS DETECTED BY THE MANIFOLD ABSOLUTE PRESSURE SENSOR (VACUUM SENSOR) (FOR MANIFOLD PRESSURE) AND IS INPUT AS A CONTROL SIGNAL TO TERMINAL PIM OF THE ENGINE CONTROL MODULE (ECU). (11) STA SIGNAL CIRCUIT TO CONFIRM WHETHER THE ENGINE IS CRANKING, THE VOLTAGE APPLIED TO THE STARTER MOTOR DURING CRANKING IS DETECTED AND THE SIGNAL IS INPUT INTO TERMINAL STA OF THE ENGINE CONTROL MODULE (ECU) AS A CONTROL SIGNAL. (12) ENGINE KNOCK SIGNAL CIRCUIT ENGINE KNOCKING IS DETECTED BY KNOCK SENSOR AND THE SIGNAL IS INPUT INTO TERMINAL KNK AS A CONTROL SIGNAL. (13) ELECTRICAL LOAD SIGNAL SYSTEM THE SIGNAL WHEN SYSTEMS SUCH AS THE REAR WINDOW DEFOGGER, HEADLIGHTS, ETC. WHICH CAUSE A HIGH ELECTRICAL BURDEN ARE ON IS INPUT TO TERMINAL ELS AS A CONTROL SIGNAL. 88 2. CONTROL SYSTEM * MFI (MULTIPORT FUEL INJECTION (EFI)) SYSTEM THE MFI (EFI) SYSTEM MONITORS THE ENGINE CONDITION THROUGH THE SIGNALS INPUT FROM EACH SENSOR (INPUT SIGNALS FROM (1) TO (13) ETC.) TO THE ENGINE CONTROL MODULE (ECU). THE BEST FUEL INJECTION VOLUME IS DECIDED BASED ON THIS DATA AND THE PROGRAM MEMORIZED BY THE ENGINE CONTROL MODULE (ECU), AND THE CONTROL SIGNAL IS OUTPUT TO TERMINALS #10, #20, #30 AND #40 (CALIFORNIA), TERMINALS #10 AND #20 (EX. CALIFORNIA) OF THE ENGINE CONTROL MODULE (ECU) TO OPERATE THE INJECTOR. (INJECT THE FUEL). THE MFI (EFI) SYSTEM PRODUCES CONTROL OF FUEL INJECTION OPERATION BY THE ENGINE CONTROL MODULE (ECU) IN RESPONSE TO THE DRIVING CONDITIONS. * ESA (ELECTRONIC SPARK ADVANCE) SYSTEM THE ESA SYSTEM MONITORS THE ENGINE CONDITION THROUGH THE SIGNALS INPUT TO THE ENGINE CONTROL MODULE (ECU) FROM EACH SENSOR (INPUT SIGNALS FROM (1), (2), (4) TO (12) ETC.) THE BEST IGNITION TIMING IS DETECTED ACCORDING TO THIS DATA AND THE MEMORIZED DATA IN THE ENGINE CONTROL MODULE (ECU) AND THE CONTROL SIGNAL IS OUTPUT TO TERMINAL IGT. THIS SIGNAL CONTROLS THE IGNITER TO PROVIDE THE BEST IGNITION TIMING FOR THE DRIVING CONDITIONS. * IAC (IDLE AIR CONTROL (ISC)) SYSTEM THE IAC (ISC) SYSTEM (ROTARY SOLENOID TYPE) INCREASES THE RPM AND PROVIDES IDLING STABILITY FOR FAST IDLE–UP WHEN THE ENGINE IS COLD AND WHEN THE IDLE SPEED HAS DROPPED DUE TO ELECTRICAL LOAD, ETC. THE ENGINE CONTROL MODULE (ECU) EVALUATES THE SIGNALS FROM EACH SENSOR (INPUT SIGNALS (1), (4) TO (8), (13) ETC.), OUTPUTS CURRENT TO TERMINALS ISCO AND ISCC, AND CONTROLS THE IDLE AIR CONTROL VALVE (ISC VALVE). * FUEL PUMP CONTROL SYSTEM THE ENGINE CONTROL MODULE (ECU) OPERATION OUTPUTS TO TERMINAL FC AND CONTROLS THE CIRCUIT OPENING RELAY AND THUS CONTROLS THE FUEL PUMP DRIVE SPEED IN RESPONSE TO CONDITIONS. * A/C IDLE–UP SYSTEM IN ORDER TO PREVENT THE ENGINE IDLING SPEED FROM DROPPING WHEN THE A/C IS OPERATING, THE A/C IDLE–UP SYSTEM CONTROLS THE VSV (FOR A/C IDLE–UP) TO INCREASE THE ENGINE IDLING SPEED AND KEEP IT STABLE. * EGR CONTROL SYSTEM THE EGR CUT CONTROL SYSTEM CONTROLS THE VSV (FOR EGR) BY EVALUATING THE SIGNALS FROM EACH SENSOR INPUT TO THE ENGINE CONTROL MODULE (ECU) (INPUT SIGNALS (1), (5), (6), (9) ETC.) AND BY SENDING OUTPUT TO TERMINAL THG OF THE ENGINE CONTROL MODULE (ECU). * A/C CUT CONTROL SYSTEM WHEN THE VEHICLE SUDDENLY ACCELERATES FROM LOW ENGINE SPEED, THIS SYSTEM CUTS OFF AIR CONDITIONING OPERATION FOR A FIXED PERIOD OF TIME IN RESPONSE TO THE VEHICLE SPEED AND THROTTLE VALVE OPENING ANGLE IN ORDER TO MAINTAIN ACCELERATION PERFORMANCE. THE ENGINE CONTROL MODULE (ECU) RECEIVES INPUT SIGNALS ((5), (6) ETC.), AND OUTPUTS SIGNALS TO TERMINAL ACT. 3. DIAGNOSIS SYSTEM WITH THE DIAGNOSIS SYSTEM, WHEN THERE IS A MALFUNCTIONING IN THE ENGINE CONTROL MODULE (ECU) SIGNAL SYSTEM, THE MALFUNCTION SYSTEM IS RECORDED IN THE MEMORY. THE MALFUNCTIONING SYSTEM CAN THEN BE FOUND BY READING THE DISPLAY (CODE) OF THE MALFUNCTION INDICATOR LAMP (CHECK ENGINE WARNING LIGHT). 4. FAIL–SAFE SYSTEM WHEN A MALFUNCTION OCCURS IN ANY SYSTEM, IF THERE IS A POSSIBILITY OF ENGINE TROUBLE BEING CAUSED BY CONTINUED CONTROL BASED ON THE SIGNALS FROM THAT SYSTEM, THE FAIL–SAFE SYSTEM EITHER CONTROLS THE SYSTEM BY USING DATA (STANDARD VALUES) RECORDED IN THE ENGINE CONTROL MODULE (ECU) MEMORY OR ELSE STOPS THE ENGINE. 89 ENGINE CONTROL (5S–FE A/T AND CALIFORNIA M/T) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 16 IP1 W–R W–R AM1 B–O W–G W–R B–O IP1 E18 B–O E18 (* 1) B–O B–O 3 1 B–O B–O 2 11 V2 VSV (FOR EGR) 3 2C 1 2 IP1 1 W–R W–L G–R G–Y LG G B–O W–B 1 A 9 C 10 C 7 C 23 C 12 A W–R E11 C , E12 B , E14 ENGINE CONTROL MODULE (ENGINE ECU)(M/T) 5 1E (* 1) B–W (* 4) (* 4) I18 I21 B–W (* 2) I2 14 1A (* 2) 6 1G B–W W B–W I18 Y 22 A B–W W (* 2) Y NSW # 30 25 C (* 5) Y (* 2) # 10 12 C B–W 1 R–B (* 1) #20 11 C Y 1 I7 INJECTOR NO. 4 I6 INJECTOR NO. 2 I5 INJECTOR NO. 3 # 40 24 C A (* 1) 2 +B ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU)(A/T) R–L W–R 2 EGR B , E10 A W (* 1) W–R 2 ISCV C ,E8 W (* 2) W–R 2 ISCO E7 Y (* 1) W–R E20 ISCC (* 5) W–R I23 BATT 1 (* 1) E17 B–O W–R 2 2B 4 (* 1) 5 (* 2) 2 V1 VSV (FOR A/C IDLE–UP) 3 2 I1 IDLE AIR CONTROL VALVE (ISC VALVE) EFI MAIN RELAY B–O W–R IP3 B–O 12 IP1 W (* 2) B–O E20 2 (* 1) 3 (* 2) E20 W (* 1) B–O 2 2D 1 1 E20 I4 INJECTOR NO. 1 B–O 4 2D B–O (EX. CALIFORNIA M/T) B–W W–R 18 I20 B–W W–B (EX. CALIFORNIA M/T) EB 90 E17 9 1D 6 1A B–W (*2) B–O 7 8 1G 1 B–O 15A EFI B–O (* 1) E17 7. 5A IGN 9 9 B–O IG1 ST1 ACC ST2 IG2 I12 IGNITION SW AM2 FROM POWER SOURCE SYSTEM (SEE PAGE 64) TO PARK/NEUTRAL POSITION SW (NEUTRAL START SW) B–O * 1 : CALIFORNIA * 2 : EX. CALIFORNIA * 4 : FOR CANADA IN TMM MADE W–R W–R * 5 : EX. * 4 W–R E20 B–O B–O B–O W–R B–O B W–R E20 TO TACHOMETER [COMB. METER] FROM POWER SOURCE SYSTEM (SEE PAGE 64) B–O 15A TAIL 10A MIR–HTR ONE BODY ASSEMBLY EX. CALIFORNIA W–R (* 1) 10 1A E19 5 3D B–R 2 3 4 5 3C 5 D2 DISTRIBUTOR 3 G2(* 1) NE–(* 2) NE 1 1 3 2 4 3 2 4 R L B Y G+ B–R 1 G– 2 A 4 C IGT 2 (* 1) (* 2) 17 C NE– G2 18 C 3 C G+ (* 2) G1 (* 1) G– G– 20 C IGF IGT E7 C ,E8 B , E10 A ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU)(A/T) E11 C , E12 B , E14 A ENGINE CONTROL MODULE (ENGINE ECU)(M/T) B–Y L I18 R I18 1 E17 THG 1 E17 BR BR 9 B 2 1 E18 BR I18 BR E18 BR BR L R E2 16 B GR 2 BR E21 10 B BR 2 FROM CRUISE CONTROL ECU THA 3 B BR THW 4 B E1 EGR GAS TEMP. SENSOR PIM 2 B I10 INTAKE AIR TEMP. SENSOR (IN–AIR TEMP. SENSOR) L–B BR 12 B L IDL 11 B B VTA 1 B BR 5 C NE+ NE R VC IGF 1 I2 IGNITER (* 2) ELS FPU IG– (SHIELDED) E4 ENGINE COOLANT TEMP. SENSOR (EFI WATER TEMP. SENSOR) LG BR B–R 8 C (*1) B–O 13 A +B W COIL– W–R G 1 2 +B1 B 1 W–R P 2 D6 DIODE (FOR IDLE–UP) V3 VSV (FOR PRESSURE UP) G B 14 1D I3 IGNITION COIL 4 3 2 1 3 VC 2 PIM 1 E2 M1 MANIFOLD ABSOLUTE PRESSURE SENSOR (VACUUM SENSOR) T1 THROTTLE POSITION SENSOR 91 ENGINE CONTROL (5S–FE A/T AND CALIFORNIA M/T) W–R W–R B–O B–O B–O B–O B B G–R G–R I13 IP3 R–L G–R C9 V–Y 10 3D TE2 TE1 7 2 1 R–W G–W Y–G TT 5 BR–B (* 3) Y–G 3 3D G–W 6 A 12 3D 18 3D R–W 3 B G–R BR A , C10 22 3D ENG 3 BR (* 4) G–R 7 3D 19 3D C B V–Y G–R R–L C J1 JUNCTION CONNECTOR C8 COMBINATION METER 4 E1 G–R (* 4) SPEED 6 1B G–R (* 5) 12 W D3 DATA LINK CONNECTOR 2 (TDCL) 1D R–L 5 8 MALFUNCTION INDICATOR LAMP (CHECK ENGINE WARNING LIGHT) [COMB. METER] IP3 (* 4) 6 TO PARK/NEUTRAL POSITION SW (NEUTRAL START SW) TO GENERATOR (ALTERNATOR) 14 G IP3 I13 10A GAUGE R–L 3 LG 2 G–R 2 (* 5) 1 G–B 11 R–L I18 P V5 VEHICLE SPEED SENSOR (SPEED SENSOR) R–L FROM POWER SOURCE SYSTEM (SEE PAGE 64) BR (SHIELDED) 9 A 5 A SP1 W E7 C ,E8 B , E10 A ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU)(A/T) E11 C , E12 B , E14 A ENGINE CONTROL MODULE (ENGINE ECU)(M/T) 1 ACT ACA KNK E16 BR E15 BR BR W (SHIELDED) 13 B 2 O2 OXYGEN SENSOR (SUB) 1 K1 KNOCK SENSOR A10 A/C AMPLIFIER 1 R–L 7 E02 26 C W–B E01 13 C W–B B–Y ACA 10 A LG–B ACT 21 A R–L BR BR ED 92 *1 *2 *3 *4 : : : : CALIFORNIA EX. CALIFORNIA EX. CALIFORNIA M/T FOR CANADA IN TMM MADE * 5 : EX. * 4 FROM POWER SOURCE SYSTEM (SEE PAGE 64) W–R B–O B–O 10A STARTER 12 13 R–W VF1 4 OX1 4 E1 3 2 3C 20 3B B–W B–O L–B G–W IP1 6 I18 15 6 IP3 2 R–W 19 IP3 R–W BR 16 IP3 BR 3 I18 G–W R–W B–W 15 B 14 B 8 B 11 A L–B W–R GR (SHIELDED) (* 3) BR–B CIRCUIT OPENING RELAY 1 4 6 C ,E8 B , E10 TE2 VF STA A A 1 (SHIELDED) FC 5 B 6 B 14 A G–R BR 14 C OX1 W OX2 R–L E1 2 W 4 BX1 L–B I18 (SHIELDED) BR I18 F15 FUEL PUMP (SHIELDED) W BR (SHIELDED) I18 M 5 1 1M R–L BR BR 1 R–L O3 OXYGEN SENSOR (MAIN) BR BR 5 BX1 (SHIELDED) W–B BR BR BR E16 BR BR 18 3C W–B I18 13 3A 11 1C 4 I18 E17 IJ1 BR BR I18 16 L–B B , E14 ENGINE CONTROL MODULE (ENGINE ECU)(M/T) N1 NOISE FILTER (FOR IGNITION SYSTEM) C , E12 W–B ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU)(A/T) E11 6 W–B E7 TE1 L–B TT 6 G–R 7 B 6 W–B 1 BR W I18 R–L 2 3D GR IP3 G–W OX2 15 IP1 I18 (* 3) 13 Y–G (* 3) BR–B BR–B IP1 (* 3) TE2 9 1 FP B–W 15 BR–B TE1 8 G–W TT GR IG– W +B D1 DATA LINK CONNECTOR 1 (CHECK CONNECTOR) 17 4 1 B–W 19 2 L–B B–O G–R B–O 19 IP1 G–R B–O B BR EC ED BL IG 93 ENGINE CONTROL (5S–FE A/T AND CALIFORNIA M/T) SERVICE HINTS E 7(C), E 8(B), E10(A) ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) (A/T) E11(C), E12(B), E14(A) ENGINE CONTROL MODULE (ENGINE ECU) (M/T) VOLTAGE AT ENGINE CONTROL MODULE (ECU) WIRING CONNECTOR BATT – E1 : ALWAYS 9.0–14.0 VOLTS +B – E1 : 9.0–14.0 VOLTS (IGNITION SW AT ON POSITION) +B1 – E1 : 9.0–14.0 VOLTS (IGNITION SW AT ON POSITION) IDL – E2 : 9.0–14.0 VOLTS (IGNITION SW ON AND THROTTLE VALVE OPEN) VC – E2 : 4.5– 5.5 VOLTS (IGNITION SW AT ON POSITION) VTA – E2 : 0.3– 0.8 VOLTS (IGNITION SW ON AND THROTTLE VALVE FULLY CLOSED) : 3.2– 4.9 VOLTS (IGNITION SW ON AND THROTTLE VALVE OPEN) PIM – E2 : 3.3– 3.9 VOLTS (IGNITION SW AT ON POSITION) #10, #20 – E01, E02 : 9.0–14.0 VOLTS (IGNITION SW AT ON POSITION) (EX. CALIFORNIA) #10, #20, #30, #40 – E01, E02 : 9.0–14.0 VOLTS (IGNITION SW AT ON POSITION) (CALIFORNIA) THA – E2 : 0.5– 3.4 VOLTS (IGNITION SW ON AND INTAKE AIR TEMP. 20°C, 68°F) THW – E2 : 0.2– 1.0 VOLTS (IGNITION SW ON AND COOLANT TEMP. 80°C, 176°F) STA – E1 : 6.0–14.0 VOLTS (ENGINE CRANKING) IGT – E1 : PULSE GENERATION (ENGINE CRANKING OR IDLING) W – E1 : 9.0–14.0 VOLTS (NO TROUBLE AND ENGINE RUNNING) ACT – E1 : 9.0–14.0 VOLTS (IGNITION SW ON AND AIR CONDITIONING ON) ACA – E1 : 7.5–14.0 VOLTS (IGNITION SW ON AND AIR CONDITIONING ON) TE1 – E1 : 9.0–14.0 VOLTS (IGNITION SW ON) NSW – E1 : 0– 3.0 VOLTS (IGNITION SW ON AND PARK/NEUTRAL POSITION SW (NEUTRAL START SW) POSITION P OR N POSITION) 9.0–14.0 VOLTS (IGNITION SW ON AND EX. PARK/NEUTRAL POSITION SW (NEUTRAL START SW) POSITION P OR N POSITION) RESISTANCE AT ENGINE CONTROL MODULE (ECU) WIRING CONNECTORS (DISCONNECT WIRING CONNECTOR) IDL – E2 : INFINITY (THROTTLE VALVE OPEN) 2.3 KΩ OR LESS (THROTTLE VALVE FULLY CLOSED) VTA – E2 : 3.3 –10.0 KΩ (THROTTLE VALVE FULLY OPEN) 0.2 – 0.8 KΩ (THROTTLE VALVE FULLY CLOSED) VC – E2 : 3.0 –7 0 KΩ THA – E2 : 2.0 –3.0 KΩ (INTAKE AIR TEMP. 20°C, 68°F) THW – E2 : 0.2 –0.4 KΩ (COOLANT TEMP. 80°C, 176°F) G1, NE – G– : 0.17–0.21 KΩ ISCC, ISCO– +B, +B1 : 19.3–22.3 Ω : PARTS LOCATION CODE SEE PAGE A10 C8 CODE SEE PAGE 32 E11 A 32 CODE SEE PAGE J1 33 32 E12 C 32 K1 31 C9 A 32 E14 B 32 M1 31 C10 C 32 F15 A 34 (S/D), 35 (C/P), 36 (W/G) N1 31 D1 30 I1 31 O2 31 D2 30 I2 31 O3 31 D3 32 I3 31 T1 31 D6 32 I4 31 V1 31 E1 30 I5 31 V2 31 E4 30 I6 31 V3 31 V5 31 E7 C 32 I7 31 E8 B 32 I10 31 E10 A 32 I12 33 : RELAY BLOCKS CODE 94 SEE PAGE RELAY BLOCKS (RELAY BLOCK LOCATION) 1 25 R/B NO. 1 (LEFT KICK PANEL) 6 26 R/B NO. 6 (BEHIND GLOVE BOX) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1A 1B 1C 1D 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 22 ENGINE WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO NO. 3 (BEHIND COMBINATION METER) 1G 1M 2D 3A 3B 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE IJ1 IP1 IP3 SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) 42 FLOOR NO. 1 WIRE AND COWL WIRE 44 ENGINE WIRE AND COWL WIRE 46 (S/D) BX1 48 (C/P) FUEL GAUGE WIRE AND FLOOR NO. 1 WIRE 50 (W/G) : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION EB 40 (5S–FE) FRONT LEFT FENDER EC 40 (5S–FE) INTAKE MANIFOLD RH ED 40 (5S–FE) INTAKE MANIFOLD LH IG 42 INSTRUMENT PANEL BRACE LH 46 (S/D) BL 48 (C/P) UNDER THE LEFT QUARTER PILLAR 50 (W/G) : SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS CODE E15 I2 E16 I13 E17 E18 E19 40 (5S–FE) (5S FE) ENGINE WIRE I18 I20 I23 SEE PAGE WIRE HARNESS WITH SPLICE POINTS 44 COWL WIRE 44 ENGINE WIRE 44 COWL WIRE E20 95 ENGINE CONTROL (5S–FE A/T AND CALIFORNIA M/T) 96 * 1 : CALIFORNIA 2 : EX. CALIFORNIA ENGINE CONTROL (5S–FE M/T EX. CALIFORNIA) 97 ENGINE CONTROL (5S–FE M/T EX. CALIFORNIA) W–R FROM POWER SOURCE SYSTEM (SEE PAGE 64) B–O AM1 15A EFI 7. 5A IGN B–O I12 IGNITION SW IG1 ST1 ACC 9 1D A4 2C B–O B–O 9 18 IP1 B–O B–O E20 E18 B–O E18 B–O E17 B–O B–O 8 1G W–G ST2 IG2 AM2 B–O E17 11 3 1 2 1 2 W–R G–Y LG G 2 C 9 A 10 A 1 A 23 A B–O B–O G–R W–B W–L I23 W–R E20 1 IP1 B–O 5 3 2C W–R 2 2 2B 2 V2 VSV (FOR EGR) I1 IDLE AIR CONTROL VALVE (ISC VALVE) W–R EFI MAIN RELAY IP1 B–O 3 I20 9 B–O IP3 V1 VSV (FOR A/C IDLE–UP) 1 12 B–O W–R 2 2D B–O 6 1A W–R E20 E20 E11 1 2 25 A A , E12 ISCV 7 C +B EGR B , E14 C # 10 12 A VC 11 B VTA 10 B IDL 12 B L B R W FROM CRUISE CONTROL ECU Y 2 I7 INJECTOR NO. 4 1 I5 INJECTOR NO. 2 I6 INJECTOR NO. 3 I4 INJECTOR NO. 1 1 2 ISCO ENGINE CONTROL MODULE (ENGINE ECU) # 20 2 ISCC W–R W–R W–R W–R BATT 1 L Y Y W W I18 R I18 4 EB 98 3 2 W W–B I18 L R I18 T1 THROTTLE POSITION SENSOR BR 1 16 IP1 W–R W–R W–R W–R E20 B–O B–O B–O W–R B–O FROM POWER SOURCE SYSTEM (SEE PAGE 64) B W–R E20 B 10 1A W–R 14 1D 10A MIR–HTR TO TACHOMETER [COMB. METER] 15A TAIL B G I3 IGNITION COIL E19 D2 DISTRIBUTOR G+ 2 3 4 Y G– 1 B NE– B 4 +B IGF IGT 1 2 W NE 1 3 I2 IGNITER L D6 B–O 3 5 COIL– R DIODE (FOR IDLE–UP) G B–R W–R 2 W–R 1 5 3C B–R P 5 3D B–R B–O 2 (SHIELDED) 4 A NE+ A , E12 B , E14 C G– 22 A IGF IGT 2 2 2 E2 9 B 1 BR 1 BR BR 1 E21 16 B BR 13 B GR THG 3 B L–B THA 4 B E4 ENGINE COOLANT TEMP. SENSOR (EFI WATER TEMP. SENSOR) B–Y G+ ENGINE CONTROL MODULE (ENGINE ECU) THW 2 B 3 A 5 A LG PIM 18 A NE– E1 EGR GAS TEMP. SENSOR E11 17 A BR ELS I10 INTAKE AIR TEMP. SENSOR (IN–AIR TEMP. SENSOR) +B1 (*2) 12 C 1 C R BR E17 BR BR E17 BR E18 BR I18 BR E18 BR BR 3 VC 2 PIM 1 E2 M1 MANIFOLD ABSOLUTE PRESSURE SENSOR (VACUUM SENSOR) 99 ENGINE CONTROL (5S–FE M/T EX. CALIFORNIA) W–R W–R B–O B–O B–O B–O B B G–R G–R G 12 R–L C R–L G–B R–L 5 C 9 A , C10 B MALFUNCTION INDICATOR LAMP (CHECK ENGINE WARNING LIGHT) [COMB. METER] C8 COMBINATION METER V–Y Y–G 3 3D I13 6 A SPEED METER 4 1 E1 C IP3 TE1 2 G–W 2 TE2 7 R–W IP3 ENG 3 G–W 12 3D 3 B 7 3D 19 3D R–W G–R 22 3D G–R 14 6 1B G–R IP3 W D3 DATA LINK CONNECTOR 2 (TDCL) G–R 11 8 BR R–L G–R (* 2) 6 1D R–L I18 10A GAUGE R–L P TO BACK–UP LIGHT SW TO GENERATOR (ALTERNATOR) J1 JUNCTION CONNECTOR 1 R–L 3 LG 2 G–R V5 VEHICLE SPEED SENSOR (SPEED SENSOR) I13 (* 1) FROM POWER SOURCE SYSTEM (SEE PAGE 64) BR 18 3D V–Y 10 3D (SHIELDED) 11 C 8 C SPD W E11 A , E12 B , E14 C ENGINE CONTROL MODULE (ENGINE ECU) ACT 3 C E02 26 A E01 E1 KNK 13 A 5 B 24 A BR 6 C ACA (SHIELDED) (SHIELDED) W W–B (SHIELDED) (SHIELDED) E15 I18 7 1 ACT ACA BR BR W–B BR B–Y LG–B I18 I18 BR 1 A10 A/C AMPLIFIER K1 KNOCK SENSOR BR BR BR ED 100 * 1 : TMC MADE * 2 : TMM MADE FROM POWER SOURCE SYSTEM (SEE PAGE 64) W–R B–O B–O 1 A6 2C FP 4 VF1 OX1 OX2 13 4 15 E1 3 B–W IP3 B–W R–W GR G–W 18 G–W 1 IP1 G–W R–W 19 IP3 R–W L–B BR 15 2 3D IP3 I18 6 2 L–B W–R I18 3 BR CIRCUIT OPENING RELAY B–W R–W GR IP3 G–W BR I18 6 16 1 (SHIELDED) 4 6 7 B TE1 TE2 VF STA ENGINE CONTROL MODULE (ENGINE ECU) 1 OX1 6 B 4 C 2 W I18 13 3A 16 IJ1 BR R–L (SHIELDED) G–R W 1 B FC G–R B , E14 C OX2 6 L–B A , E12 6 2 A N1 NOISE FILTER (FOR IGNITION SYSTEM) E11 8 B 6 L–B 15 B 3B B–W GR B–O 13 IP3 R–L W 2 3C Y–G (* 2) TE2 9 B–O TE1 8 IP1 B–W B W–B 12 IG– W L–B (*1) 19 2 D1 DATA LINK CONNECTOR 1 (CHECK CONNECTOR) B–W G–R B–O 19 IP1 G–R 10A STARTER B–O B 18 3C 4 BX1 W–B R–L L–B I18 11 1C W R–L (SHIELDED) 4 BR F15 FUEL PUMP O3 OXYGEN SENSOR (MAIN) 1 M 1 1M 5 5 BX1 (SHIELDED) BR BR BR W–B E17 BR BR W–B BR W–B O2 OXYGEN SENSOR (SUB) 1 2 BR EC ED BL IG 101 ENGINE CONTROL (5S–FE M/T EX. CALIFORNIA) SERVICE HINTS E11(A), E12(B), E14(C) ENGINE CONTROL MODULE (ENGINE ECU) VOLTAGE AT ENGINE CONTROL MODULE (ECU) WIRING CONNECTOR BATT – E1 : ALWAYS 9.0–14.0 VOLTS +B – E1 : 9.0–14.0 VOLTS (IGNITION SW AT ON POSITION) +B1 – E1 : 9.0–14.0 VOLTS (IGNITION SW AT ON POSITION) IDL – E1 : 9.0–14.0 VOLTS (IGNITION SW ON AND THROTTLE VALVE OPEN) PIM – E2 : 3.3– 3.9 VOLTS (IGNITION SW AT ON POSITION) #10, #20 – E01, E02 : 9.0–14.0 VOLTS (IGNITION SW AT ON POSITION) THA – E2 : 0.5– 3.4 VOLTS (IGNITION SW ON AND INTAKE AIR TEMP. 20°C, 68°F) THW – E2 : 0.2– 1.0 VOLTS (IGNITION SW ON AND COOLANT TEMP. 80°C, 176°F) STA – E1 : 6.0–14.0 VOLTS (ENGINE CRANKING) IGT – E1 : 0.8–1.2 VOLTS (ENGINE CRANKING OR IDLING) ISCC, ISCO– E1 : 8.0–14.0 VOLTS (IGNITION SW AT ON POSITION) W – E1 : 9.0–14.0 VOLTS (IGNITION SW ON, NO TROUBLE AND ENGINE RUNNING) ACT – E1 : 9.0–14.0 VOLTS (IGNITION SW ON AND AIR CONDITIONING ON) ACA – E1 : 7.5–14.0 VOLTS (IGNITION SW ON AND AIR CONDITIONING ON) TE1 – E1 : 9.0–14.0 VOLTS (IGNITION SW ON) RESISTANCE AT ENGINE CONTROL MODULE (ECU) WIRING CONNECTORS (DISCONNECT WIRING CONNECTOR) IDL – E1 : INFINITY (THROTTLE VALVE OPEN) 0 Ω (THROTTLE VALVE FULLY CLOSED) THA – E2 : 2.0 –3.0 KΩ (INTAKE AIR TEMP. 20°C, 68°F) THW – E2 : 0.2 –0.4 KΩ (COOLANT TEMP. 80°C, 176°F) G+ – G– : 0.17–0.21 KΩ ISCC, ISCO– +B, +B1 : 19.3–22.3 KΩ : PARTS LOCATION CODE SEE PAGE A10 32 C8 CODE E14 SEE PAGE C CODE SEE PAGE 30 K1 31 32 F15 34 (S/D), 35 (C/P), 36 (W/G) M1 31 C9 A 32 I1 31 N1 31 C10 B 32 I2 31 O2 31 D1 30 I3 31 O3 31 D2 30 I4 31 T1 31 D3 32 I5 31 V1 31 D6 32 I6 31 V2 31 E1 30 I7 31 V3 31 E4 30 I10 31 V5 31 E11 A 30 I12 33 E12 B 30 J1 33 : RELAY BLOCKS CODE 6 SEE PAGE 26 RELAY BLOCKS (RELAY BLOCK LOCATION) R/B NO. 6 (BEHIND GLOVE BOX) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1A 1B 1C 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 2A 22 ENGINE ROOM MAIN WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 2C 22 ENGINE WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO. 3 (BEHIND COMBINATION METER) 1D 1G 1M 3A 3C 3D 102 : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE IJ1 IP1 IP3 SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) 42 FLOOR NO. 1 WIRE AND COWL WIRE 44 ENGINE WIRE AND COWL WIRE 46 (S/D) BX1 48 (C/P) FUEL GAUGE WIRE AND FLOOR NO. 1 WIRE 50 (W/G) : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION EB 40 (5S–FE) FRONT LEFT FENDER EC 40 (5S–FE) INTAKE MANIFOLD RH ED 40 (5S–FE) INTAKE MANIFOLD LH IG 42 INSTRUMENT PANEL BRACE LH 46 (S/D) BL 48 (C/P) UNDER THE LEFT QUARTER PILLAR 50 (W/G) : SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS E15 E20 40 (5S–FE) ENGINE WIRE E16 I13 44 COWL WIRE I18 44 ENGINE WIRE 44 COWL WIRE E17 40 (5S–FE) (5S FE) ENGINE WIRE E18 I20 E19 I23 103 W–B 104 LOW W–B LIGHT CONTROL SW C12 COMBINATION SW 11 R–B 4 W FL MAIN 2. 0L 3 R–B 13 14 IE I5 14 I2 R–B R–Y 2 R 1 1 H3 HEADLIGHT LO LH W–B 13 R 5 ED1 5 2A R–Y E4 1 2A H4 HEADLIGHT LO RH W–B 2 2A R–Y R–Y 1 1 2E H2 HEADLIGHT HI RH R–B R–Y R–B 2 2E 3 7 2G C9 HIGH BEAM INDICATOR LIGHT [COMB. METER] R–B R–B 2 2H R–B R–Y I13 INTEGRATION RELAY BATTERY 40A MAIN 2 1 2 H1 HEADLIGHT HI LH R–B 4 W–B W–B DIMMER SW B HEADLIGHT (FOR USA) 15A HEAD (RH) 15A HEAD (LH) HEADLIGHT RELAY 2 6 2A 1 2 E3 E4 8 ED1 OFF 12 TAIL HEAD HIGH FLASH 9 I5 EB SERVICE HINTS HEADLIGHT RELAY 2–1 : CLOSED WITH LIGHT CONTROL SW AT HEAD POSITION OR DIMMER SW AT FLASH POSITION LIGHT AUTO TURN OFF OPERATION PLEASE REFER TO THE LIGHT AUTO TURN OFF SYSTEM (SEE PAGE 102) : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE CODE C9 32 H2 28 (1MZ–FE), 30 (5S–FE) C12 32 H3 28 (1MZ–FE), 30 (5S–FE) H1 28 (1MZ–FE), 30 (5S–FE) H4 28 (1MZ–FE), 30 (5S–FE) I13 SEE PAGE 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 2A 22 ENGINE ROOM MAIN WIRE AND J/B NO NO. 2 (ENGINE COMPARTMENT LEFT) 2G 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 2H 22 ENGINE WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 2E : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) 38 (1MZ–FE) ED1 COWL WIRE AND ENGINE ROOM MAIN WIRE 40 (5S–FE) : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION 38 (1MZ–FE) EB IE FRONT LEFT FENDER 40 (5S–FE) 42 LEFT KICK PANEL : SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS CODE 38 (1MZ–FE) E3 E4 40 (5S–FE) E4 SEE PAGE ENGINE ROOM MAIN WIRE 44 COWL WIRE I2 ENGINE ROOM MAIN WIRE 38 (1MZ–FE) I5 C9 C12 BLACK X X X 1 X H 1, H 2 X 13 14 X H 3, H 4 BROWN WIRE HARNESS WITH SPLICE POINTS 40 (5S–FE) 9 11 1 BLACK 2 12 13 14 I13 2 3 4 105 HEADLIGHT (FOR CANADA) W B 2 B W 2H 4 2 40A MAIN HEADLIGHT RELAY R–B 1 1 2E W 3 2G I7 R–B L–Y I13 INTEGRATION RELAY 4 3 3 7 2G R–B W 15A ECU–B 4 EF1 2 R–B 13 2 14 5 G–R 15 OFF TAIL HEAD LOW HIGH W–B 11 9 12 R–Y FLASH W–B DIMMER SW B B 2 C B G R–Y C12 COMBINATION SW LIGHT CONTROL SW 100A ALT C B , F16 A , F10 F10 FUSE BOX I7 L–Y 9 3A R–B 1 A (1MZ–FE) 1 B (5S–FE) 11 3B G–R W 1 FL MAIN 2. 0L 16 D4 DAYTIME RUNNING LIGHT RELAY (MAIN) I5 W–B BATTERY W–B W–B I5 IE 106 W–B W W B B W W FROM POWER SOURCE SYSTEM (SEE PAGE 64) 6 EC1 B R–L 4 1E 5 1 5 DAYTIME RUNNING LIGHT RELAY NO. 2 TAILLIGHT RELAY 10A GAUGE 3 8 1B 5 R–L 7 1B 2 5 R 2 3 R–L 1 8 ED1 G–R 17 3A R–L R 18 3A D4 DAYTIME RUNNING LIGHT RELAY (MAIN) R–W 1 P3 PARKING BRAKE SW W–B R–W A R–Y (1MZ–FE) II1 (5S–FE) TO GENERATOR (ALTERNATOR) ” L” 4 12 3A 1 P2 PARKING BRAKE SW FROM COMBINATION METER R–W 8 3C R–W 8 3D A 18 3C W–B 10 3A 13 W–B 18 W–B 11 1C 1 1M W–B 8 17 R–Y 11 Y 2 J1 JUNCTION CONNECTOR G–R IG 107 HEADLIGHT (FOR CANADA) W E6 1 EB1 E7 W W W R–L W W 2 2E 7 5 2 1 15A HEAD (LWR–LH) 7. 5A DRL 2 2A R 2 7 4 3 7 R–G 7 3 EB1 7 W–B 4 1 3 2 E3 W–B W–B R–B W–B R–G 13 14 5 EB1 4 EB1 W–B C9 HIGH BEAM INDICATOR LIGHT [COMB. METER] R–G 2 R–B H2 HEADLIGHT HI RH R–B R–B H1 HEADLIGHT HI LH 2 R–B E4 W–B W–B W–B W–B E4 EB 108 2 7 7 5 ED1 1 R–W 2 W–B R–G 1 W–B 1 7 7 DAYTIME RUNNING LIGHT RELAY NO. 3 7 5 1 R–B H3 HEADLIGHT LO LH W–R 2 1 5 R R 7 E4 5 DAYTIME RUNNING LIGHT RELAY NO. 4 2 EB1 R–G 4 W–R 5 2A R–B 1 15A HEAD (LWR–RH) H4 HEADLIGHT LO RH 15A HEAD (UPR–RH) 3 W–B 15A HEAD (UPR–LH) 5 SYSTEM OUTLINE CURRENT FROM THE BATTERY IS ALWAYS FLOWING FROM THE FL MAIN → HEADLIGHT RELAY (COIL SIDE) → TERMINAL 5 OF THE DAYTIME RUNNING LIGHT RELAY (MAIN) AND TERMINAL 14 OF THE DIMMER SW, HEADLIGHT RELAY (COIL SIDE) → TERMINAL 3 OF THE INTEGRATION RELAY → TERMINAL 4 → TERMINAL 13 OF THE LIGHT CONTROL SW, FL MAIN → DAYTIME RUNNING LIGHT RELAY NO. 2 (COIL SIDE) → TERMINAL 17 OF THE DAYTIME RUNNING LIGHT RELAY. 1. DAYTIME RUNNING LIGHT OPERATION WHEN THE ENGINE IS STARTED, VOLTAGE GENERATED AT TERMINAL L OF THE GENERATOR (ALTERNATOR) IS APPLIED TO TERMINAL 11 OF THE DAYTIME RUNNING LIGHT RELAY (MAIN). IF THE PARKING BRAKE LEVER IS PULLED UP (PARKING BRAKE SW ON) AT THIS TIME, THE RELAY IS NOT ENERGIZED, SO THE DAYTIME RUNNING LIGHT SYSTEM DOES NOT OPERATE. IF THE PARKING BRAKE LEVER IS RELEASED (PARKING BRAKE LEVER SW OFF), THE SIGNAL IS INPUT TO TERMINAL 8 OF THE RELAY. THIS ACTIVATES THE RELAY ALSO, CURRENT FROM FL MAIN FLOWES TO DAYTIME RUNNING LIGHT RELAY NO. 2 (POINT SIDE) → HEAD (UPR–LH) FUSE → TERMINAL 1 OF THE HEAD LH–HI → TERMINAL 2 → TERMINAL 2 OF THE HEAD RH–HI → TERMINAL 1 → TERMINAL 4 OF THE DAYTIME RUNNING LIGHT RELAY NO. 3 → TERMINAL 2 → TO GROUND, SO BOTH TAIL AND HEADLIGHT UP. THIS IS HOW THE DAYTIME RUNNING LIGHT SYSTEM OPERATES. ONCE THE DAYTIME RUNNING LIGHT SYSTEM OPERATES AND HEAD HAVE LIGHT UP, HEAD REMAIN ON EVEN IF THE PARKING BRAKE LEVER IS PULLED UP (PARKING BRAKE SW ON). EVEN IF THE ENGINE STALLS WITH THE IGNITION SW ON AND THERE IS NO VOLTAGE FROM TERMINAL L OF THE GENERATOR (ALTERNATOR), HEAD REMAIN ON. IF THE IGNITION SW IS THEN TURNED OFF, AND HEAD ARE TURNED OFF. IF THE ENGINE IS STARTED WHILE THE PARKING BRAKE LEVER IS RELEASED (PARKING BRAKE SW OFF), THE DAYTIME RUNNING LIGHT SYSTEM OPERATES AND TAIL, HEADLIGHT UP AS THE ENGINE STARTS. 2. HEADLIGHT OPERATION *(WHEN THE LIGHT CONTROL SW AT THE HEAD POSITION) WHEN THE LIGHT CONTROL SW IS SET TO HEAD POSITION, THE CURRENT FLOWING TO THE HEADLIGHT RELAY (COIL SIDE) FLOWS TO TERMINAL 3 OF THE INTEGRATION RELAY → TERMINAL 4 → TERMINAL 13 OF THE LIGHT CONTROL SW → TERMINAL 11 → GROUND, TURNING THE HEADLIGHT RELAY ON. THIS CAUSES THE CURRENT FLOWING TO THE HEADLIGHT RELAY (POINT SIDE) → DRL FUSE → DAYTIME RUNNING LIGHT RELAY NO. 3 (COIL SIDE) AND DAYTIME RUNNING LIGHT RELAY NO. 4 (COIL SIDE) → GROUND, TURNING THE DAYTIME RUNNING LIGHT RELAY NO. 3 AND NO. 4 ON. ALSO, CURRENT FROM THE HEADLIGHT RELAY (POINT SIDE) TO HEAD (LWR) FUSES → TERMINAL 1 OF THE HEADLIGHTS (LO) → TERMINAL 2 → GROUND, SO THE HEADLIGHTS (LO) LIGHT UP. *(DIMMER SW AT FLASH POSITION) WHEN THE DIMMER SW IS SET TO FLASH POSITION, CURRENT FLOWS FROM HEADLIGHT RELAY (COIL SIDE) → TERMINAL 14 OF THE DIMMER SW → TERMINAL 9 → GROUND, TURNING THE HEADLIGHT RELAY ON. AT THE SAME TIME, SIGNALS ARE OUTPUT FROM TERMINAL 12 AND TERMINAL 14 OF THE DIMMER SW TO TERMINAL 16 AND TERMINAL 5 OF THE DAYTIME RUNNING LIGHT RELAY (MAIN), ACTIVATING THE DAYTIME RUNNING LIGHT RELAY (MAIN) AND ALSO THE DAYTIME RUNNING LIGHT RELAY NO. 2. WHEN THE HEADLIGHT RELAY AND DAYTIME RUNNING LIGHT RELAY (MAIN) ARE ACTIVATED, THE HEADLIGHTS (LO AND HI) THEN LIGHT UP. *(DIMMER SW AT HIGH POSITION) WHEN THE LIGHT CONTROL SW IS SET TO HEAD POSITION, A SIGNAL IS OUTPUT FROM TERMINAL 13 OF THE LIGHT CONTROL SW → TERMINAL 4 OF THE INTEGRATION RELAY → TERMINAL 3 → TERMINAL 5 OF THE DAYTIME RUNNING LIGHT RELAY (MAIN). WHEN THE DIMMER SW IS SET TO HIGH POSITION, A SIGNAL IS OUTPUT FROM TERMINAL 12 OF THE DIMMER SW TO TERMINAL 16 OF THE DAYTIME RUNNING LIGHT RELAY (MAIN). THESE SIGNALS ACTIVATE DAYTIME RUNNING LIGHT RELAY NO. 2, SO CURRENT FLOWS FROM DAYTIME RUNNING LIGHT RELAY NO. 2 (POINT SIDE) → HEAD (UPR–LH) FUSE → TERMINAL 1 OF THE HEADLIGHT LH–HI → TERMINAL 2 → DAYTIME RUNNING LIGHT RELAY NO. 4 (POINT SIDE) → GROUND, AND CURRENT ALSO SIMUTANEOUSLY FLOWS FROM HEAD (UPR–RH) FUSE → DAYTIME RUNNING LIGHT RELAY NO. 3 (POINT SIDE) → TERMINAL 1 OF THE HEADLIGHT RH–HI → TERMINAL 2 → DAYTIME RUNNING LIGHT RELAY NO. 4 (POINT SIDE), CAUSING THE HEADLIGHTS (HI SIDE) TO LIGHT UP. SERVICE HINTS D 4 DAYTIME RUNNING LIGHT RELAY (MAIN) 2–GROUND 15–GROUND 8–GROUND 13–GROUND : : : : APPROX. 12 VOLTS WITH THE IGNITION SW AT ON POSITION ALWAYS APPROX. 12 VOLTS CONTINUITY WITH THE PARKING BRAKE LEVER PULLED UP (PARKING BRAKE SW ON) ALWAYS CONTINUITY 109 HEADLIGHT (FOR CANADA) : PARTS LOCATION CODE SEE PAGE CODE C9 32 C12 32 H1 D4 32 H2 A 28 (1MZ–FE), 30 (5S–FE) B 28 (1MZ–FE), 30 (5S–FE) F10 F16 SEE PAGE C CODE 28 (1MZ–FE), 30 (5S–FE) SEE PAGE I13 33 28 (1MZ–FE), 30 (5S–FE) J1 33 28 (1MZ–FE), 30 (5S–FE) P2 33 H3 28 (1MZ–FE), 30 (5S–FE) P3 33 H4 28 (1MZ–FE), 30 (5S–FE) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1B 1C 1D 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 22 ENGINE ROOM MAIN WIRE AND J/B NO NO. 2 (ENGINE COMPARTMENT LEFT) 2G 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 2H 22 ENGINE WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO NO. 3 (BEHIND COMBINATION METER) 1E 1M 2A 2E 3A 3B 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE EB1 EC1 ED1 EF1 II1 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) 42 JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ENGINE ROOM MAIN WIRE AND RELAY WIRE ENGINE WIRE AND ENGINE ROOM MAIN WIRE COWL WIRE AND ENGINE ROOM MAIN WIRE ENGINE WIRE AND COWL WIRE COWL WIRE AND INSTRUMENT PANEL WIRE : GROUND POINTS CODE EB SEE PAGE 38 (1MZ–FE) 40 (5S–FE) GROUND POINTS LOCATION FRONT LEFT FENDER IE 42 LEFT KICK PANEL IG 42 INSTRUMENT PANEL BRACE LH : SPLICE POINTS CODE E3 E4 E6 110 SEE PAGE WIRE HARNESS WITH SPLICE POINTS 38 (1MZ–FE) E6 40 (5S–FE) 38 (1MZ–FE) CODE ENGINE ROOM MAIN WIRE E7 40 (5S–FE) I5 38 (1MZ–FE) I7 SEE PAGE WIRE HARNESS WITH SPLICE POINTS 40 (5S–FE) 38 (1MZ–FE) ENGINE ROOM MAIN WIRE 40 (5S–FE) 44 COWL WIRE 111 * 1 : 1MZ–FE * 2 : 5S–FE LIGHT AUTO TURN OFF FROM POWER SOURCE SYSTEM (SEE PAGE 64) B W 4 1E 2 2H 1 5 4 20A DOME 2 TAILLIGHT RELAY 10A GAUGE 2 3 3 TO TAIL FUSE 8 1B C12 BLACK HEADLIGHT RELAY FROM POWER SOURCE SYSTEM (SEE PAGE 64) 2 X 1 7 2G 2 2G X X 11 TO HEAD FUSE R R–B G–R D12 1 EF1 1 1 1C 2 A 1 3 A (* 1) F10 A (* 2) F10 B S R Q R S Q 100A ALT 1 A (* 1) 1 B (* 2) FUSE BOX F10 A , F10 B , F16 C W 7 6 1 C I13 1 A A 4 A G INTEGRATION RELAY 10 1 1M B C12 COMBINATION SW LIGHT CONTROL SW R–G B R–Y 2 1H FL MAIN 2. 0L 2 13 OFF 1 TAIL HEAD 11 1 F16 C D12 DOOR COURTESY SW FRONT LH 1 W–B W–B BATTERY I13 A 1 2 3 4 IE 112 IG X 13 SYSTEM OUTLINE WITH THE IGNITION SW TURNED ON, THE CURRENT FLOWS TO TERMINAL 7 OF THE INTEGRATION RELAY THROUGH GAUGE FUSE. VOLTAGE IS APPLIED AT ALL TIMES TO TERMINAL (A) 2 OF THE INTEGRATION RELAY THROUGH THE TAILLIGHT RELAY (COIL SIDE), AND TO TERMINAL (A) 3 THROUGH THE HEADLIGHT RELAY (COIL SIDE). 1. NORMAL LIGHTING OPERATION (TURN TAILLIGHT ON) WITH LIGHT CONTROL SW TURNED TO TAILLIGHT POSITION, A SIGNAL IS INPUT INTO TERMINAL (A) 1 OF THE INTEGRATION RELAY. ACCORDING TO THIS SIGNAL, THE CURRENT FLOWING TO TERMINAL (A) 2 OF THE RELAY FLOWS FROM TERMINAL (A) 1 → TERMINAL 2 OF THE LIGHT CONTROL SW → TERMINAL 11 → TO GROUND AND TAILLIGHT RELAY CAUSES TAILLIGHT TO TURN ON. (TURN HEADLIGHT ON) WITH LIGHT CONTROL SW TURNED TO HEADLIGHT POSITION, A SIGNAL IS INPUT INTO TERMINALS (A) 1 AND (A) 4 OF THE INTEGRATION RELAY. ACCORDING TO THIS SIGNAL, THE CURRENT FLOWING TO TERMINAL (A) 3 OF THE RELAY FLOWS TO TERMINAL (A) 4 → TERMINAL 13 OF THE LIGHT CONTROL SW → TERMINAL 11 → TO GROUND IN THE HEADLIGHT CIRCUIT, AND CAUSES TAILLIGHT AND HEADLIGHT RELAY TO TURN THE LIGHT ON. THE TAILLIGHT CIRCUIT IS SAME AS ABOVE. 2. LIGHT AUTO TURN OFF OPERATION WITH LIGHTS ON AND IGNITION SW TURNED OFF (INPUT SIGNAL GOES TO TERMINAL 7 OF THE RELAY), WHEN DOOR ON DRIVER’S SIDE IS OPENED (INPUT SIGNAL GOES TO TERMINAL 6 OF THE RELAY), THE RELAY OPERATES AND THE CURRENT IS CUT OFF WHICH FLOWS FROM TERMINAL (A) 2 OF THE RELAY TO TERMINAL (A) 1 IN TAILLIGHT CIRCUIT AND FROM TERMINAL (A) 3 TO TERMINAL (A) 4 IN HEADLIGHT CIRCUIT. AS A RESULT, ALL LIGHTS ARE TURNED OFF AUTOMATICALLY. SERVICE HINTS I13 INTEGRATION RELAY (A) (A) (A) (A) 7–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 1–GROUND : ALWAYS APPROX. 12 VOLTS 3–GROUND : APPROX. 12 VOLTS WITH LIGHT CONTROL SW AT OFF OR TAIL POSITION 2–GROUND : APPROX. 12 VOLTS WITH LIGHT CONTROL SW AT OFF POSITION 6–GROUND : CONTINUITY WITH FRONT LH DOOR OPEN 4–GROUND : CONTINUITY WITH LIGHT CONTROL SW AT HEAD POSITION 1–GROUND : CONTINUITY WITH LIGHT CONTROL SW AT TAIL OR HEAD POSITION 10–GROUND : ALWAYS CONTINUITY : PARTS LOCATION CODE SEE PAGE C12 32 D12 34 (S/D), 35 (C/P), 36 (W/G) CODE F10 SEE PAGE CODE SEE PAGE A 28 (1MZ–FE), 30 (5S–FE) F16 C 28 (1MZ–FE), 30 (5S–FE) B 28 (1MZ–FE), 30 (5S–FE) I13 A 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1B 1C 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 1E 1H 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 1M 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 2G 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 2H 22 ENGINE WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE EF1 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ENGINE WIRE AND COWL WIRE : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION IE 42 LEFT KICK PANEL IG 42 INSTRUMENT PANEL BRACE LH 113 TURN SIGNAL AND HAZARD WARNING LIGHT (S/D, C/P) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 10A HAZ 2 2F W H7 HAZARD SW 2 1A L 7. 5A TURN 10 8 C12 TURN SIGNAL SW [COMB. SW] OFF RH HAZARD TURN 1 1 1 8 G–Y 5 G–W 6 G–B 5 G–Y 9 G–B 7 G–W TURN SIGNAL FLASHER 2 LH G–R ON G–B 1 G–W 3 G–Y 1 G–Y I7 G–Y I11 G–B G–Y 2 B 4 ED1 J1 JUNCTION CONNECTOR 1 ED1 4 1A LH RH B 16 1H C8 TURN SIGNAL INDICATOR LIGHT [COMB. METER] G–Y IJ1 3 G–B 9 G–Y W–B G–B F 1 W–B F J1 JUNCTION CONNECTOR G–B I11 G–Y G–B W–B G–B G–Y I7 6 3D 5 2 W–B 11 1C 1 1M W–B W–B 5 1 F8 FRONT TURN SIGANL LIGHT RH 1 18 3C W–B G–Y 1 R10 REAR TURN SIGNAL LIGHT RH [REAR COMB. LIGHT RH] 11 BZ1 W–B 2 R8 REAR TRUN SIGNAL LIGHT LH [REAR COMB. LIGHT LH] 1 W–B W–B F7 FRONT TURN SIGNAL LIGHT LH 5 1M 10 BZ1 G–B G–B 8 1C IE 114 EB BO EA IG SERVICE HINTS TURN SIGNAL FLASHER (1) 2–GROUND : APPROX. 12 VOLTS WITH IGNITION SW ON OR HAZARD SW ON (1) 1–GROUND : CHANGES FROM APPROX. 12 TO 0 VOLTS WITH IGNITION SW ON AND TURN SIGNAL SW LEFT OR RIGHT, OR HAZARD SW ON (1) 3–GROUND: ALWAYS CONTINUITY : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE CODE SEE PAGE C8 32 F8 28 (1MZ–FE), 30 (5S–FE) R8 34 (S/D), 35 (C/P) C12 32 H7 33 R10 34 (S/D), 35 (C/P) F7 28 (1MZ–FE), 30 (5S–FE) J1 33 : RELAY BLOCKS CODE 1 SEE PAGE 25 RELAY BLOCKS (RELAY BLOCK LOCATION) R/B NO. 1 (LEFT KICK PANEL) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1A 1C SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 1H 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 1M 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 2F 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO NO. 3 (BEHIND COMBINATION METER) 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE ED1 IJ1 BZ1 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 42 JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) COWL WIRE AND ENGINE ROOM MAIN WIRE FLOOR NO. 1 WIRE AND COWL WIRE 46 (S/D) 48 (C/P) LUGGAGE ROOM NO. NO 1 WIRE AND FLOOR NO. NO 1 WIRE : GROUND POINTS CODE EA EB SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) GROUND POINTS LOCATION FRONT RIGHT FENDER FRONT LEFT FENDER IE 42 LEFT KICK PANEL IG 42 INSTRUMENT PANEL BRACE LH BO 46 (S/D) 48 (C/P) LEFT QUARTER PILLAR : SPLICE POINTS CODE I7 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS COWL WIRE CODE I11 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS COWL WIRE 115 TURN SIGNAL AND HAZARD WARNING LIGHT (S/D, C/P) 116 TURN SIGNAL AND HAZARD WARNING LIGHT (W/G) 117 TURN SIGNAL AND HAZARD WARNING LIGHT (W/G) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 2 1A 2 2F W H7 HAZARD SW 10A HAZ L 7. 5A TURN 10 8 C12 TURN SIGNAL SW [COMB. SW] OFF RH HAZARD TURN 1 1 8 G–Y G–W 1 5 G–B 6 G–Y 5 G–B 9 G–W TURN SIGNAL FLASHER 2 LH 7 G–R ON G–B 1 G–W 3 1 G–Y I7 G–Y G–Y I11 G–B W–B G–B G–Y G–B J1 JUNCTION CONNECTOR G–Y 4 1A 1 ED1 LH C8 TURN SIGNAL INDICATOR LIGHT [COMB. METER] G–Y G–Y W–B C J5 JUNCTION CONNECTOR 1 2 W–B EB BL 11 1C 1 1M W–B C F8 FRONT TURN SIGANL LIGHT RH 3 18 3C W–B 3 4 R10 REAR TURN SIGNAL LIGHT RH [REAR COMB. LIGHT RH] 4 W–B 2 R8 REAR TRUN SIGNAL LIGHT LH [REAR COMB. LIGHT LH] 1 W–B F7 FRONT TURN SIGNAL LIGHT LH 5 1M W–B 6 3D 4 Bb1 G–Y G–B G–B IJ1 3 W–B 16 1H W–B 8 1C 118 RH B 2 IE 2 B 4 ED1 G–B F 1 W–B F J1 JUNCTION CONNECTOR G–B I11 G–Y I7 BQ EA IG SERVICE HINTS TURN SIGNAL FLASHER (1) 2–GROUND : APPROX. 12 VOLTS WITH IGNITION SW ON OR HAZARD SW ON (1) 1–GROUND : CHANGES FROM APPROX. 12 TO 0 VOLTS WITH IGNITION SW ON AND TURN SIGNAL SW LEFT OR RIGHT, OR HAZARD SW ON (1) 3–GROUND: ALWAYS CONTINUITY : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE CODE C8 32 F8 28 (1MZ–FE), 30 (5S–FE) C12 32 H7 F7 28 (1MZ–FE), 30 (5S–FE) J1 SEE PAGE J5 36 33 R8 36 (W/G) 33 R10 36 (W/G) : RELAY BLOCKS CODE 1 SEE PAGE 25 RELAY BLOCKS (RELAY BLOCK LOCATION) R/B NO. 1 (LEFT KICK PANEL) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1A 1C SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 1H 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 1M 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 2F 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO NO. 3 (BEHIND COMBINATION METER) 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE ED1 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) COWL WIRE AND ENGINE ROOM MAIN WIRE IJ1 42 FLOOR NO. 1 WIRE AND COWL WIRE Bb1 50 (W/G) LUGGAGE ROOM NO. 1 WIRE AND FLOOR NO. 1 WIRE : GROUND POINTS CODE EA EB SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) GROUND POINTS LOCATION FRONT RIGHT FENDER FRONT LEFT FENDER IE 42 LEFT KICK PANEL IG 42 INSTRUMENT PANEL BRACE LH 46 (S/D) BL 48 (C/P) UNDER THE LEFT QUARTER PILLAR 50 (W/G) BQ 50 (W/G) LOWER BACK PANEL CENTER : SPLICE POINTS CODE I7 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS COWL WIRE CODE I11 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS COWL WIRE 119 STOP LIGHT (S/D, C/P) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 15A STOP 3 1M 10A GAUGE 9 1H 6 1B 2 A N2 R–L G–R G–W C 1 A J1 JUNCTION CONNECTOR A , N3 B NOISE FILTER (FOR STOP LIGHT) R–L Y 1 B G–W 17 1H C 2 B G–W 6 1M 6 G–W 2 C9 REAR LIGHT WARNING INDICATOR LIGHT [COMB. METER] S10 STOP LIGHT SW B10 : S/D B26 : C/P 3 Y–G 2 BZ1 BZ1 Y G–W DELAY HOLD 8 BZ1 G–W 1 Ba1 G–R W–B W–B 1 1 H10 HIGH MOUNT STOP LIGHT 2 2 3 2 W–B W–B W–B W–B B17 : S/D B29 : C/P 4 Ba1 W–B W–B W–B 3 5 B14 : S/D B28 : C/P 120 2 R11 STOP LIGHT RH [REAR COMB. LIGHT] R9 STOP LIGHT LH [REAR COMB. LIGHT] G–R 2 B16 : S/D B29 : C/P BO G–R R G–R B16 : S/D B29 : C/P G–R 9 BZ1 (W/ REAR SPOILER) W–B Ba1 G–R W–B Y–G R W–B 5 B12 : S/D B28 : C/P G–R 2 R10 STOP LIGHT RH [REAR COMB. LIGHT RH] R8 STOP LIGHT LH [REAR COMB. LIGHT LH] B13 : S/D B28 : C/P G–R 11 3 BZ1 (W/O REAR SPOILER) 5 G–W Y–G H10 HIGH MOUNT STOP LIGHT R 4 G–W 1 G–R 2 IJ1 8 W–B G–W 17 L2 LIGHT FAILURE SENSOR 7 7 BZ1 W–B W–B B 9 : S/D B25 : C/P B10 : S/D B25 : C/P W–B G–W 1 4 BL BO SYSTEM OUTLINE CURRENT IS APPLIED AT ALL TIMES THROUGH A STOP FUSE TO TERMINAL 2 OF THE STOP LIGHT SW. WHEN THE IGNITION SW IS TURNED ON, CURRENT FLOWS FROM THE GAUGE FUSE TO TERMINAL 8 OF THE LIGHT FAILURE SENSOR, AND ALSO FLOWS THROUGH THE REAR LIGHT WARNING LIGHT TO TERMINAL 4 OF THE LIGHT FAILURE SENSOR. STOP LIGHT DISCONNECTION WARNING WHEN THE IGNITION SW IS TURNED ON AND THE BRAKE PEDAL IS PRESSED (STOP LIGHT SW ON), IF THE STOP LIGHT CIRCUIT IS OPEN, THE CURRENT FLOWING FROM TERMINALS 7 OF THE LIGHT FAILURE SENSOR TO TERMINALS 1, 2 CHANGES, SO THE LIGHT FAILURE SENSOR DETECTS THE DISCONNECTION AND THE WARNING CIRCUIT OF THE LIGHT FAILURE SENSOR IS ACTIVATED. AS A RESULT, THE CURRENT FLOWS FROM TERMINAL 4 OF THE LIGHT FAILURE SENSOR → TERMINAL 11 → GROUND AND TURNS THE REAR LIGHT WARNING LIGHT ON. BY PRESSING THE BRAKE PEDAL, THE CURRENT FLOWING TO TERMINAL 8 OF THE LIGHT FAILURE SENSOR KEEPS THE WARNING CIRCUIT ON HOLD AND THE WARNING LIGHT ON UNTIL THE IGNITION SW IS TURNED OFF. SERVICE HINTS S10 STOP LIGHT SW 2–1 : CLOSED WITH BRAKE PEDAL DEPRESSED L 2 LIGHT FAILURE SENSOR 1, 2, 7–GROUND : APPROX. 12 VOLTS WITH STOP LIGHT SW ON 4, 8–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 11–GROUND : ALWAYS CONTINUITY : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE C9 32 N2 H10 34 (S/D), 35 (C/P) N3 J1 33 R8 L2 34 (S/D), 35 (C/P) R9 34 (S/D), 35 (C/P) CODE SEE PAGE A 33 R10 34 (S/D), 35 (C/P) B 33 R11 34 (S/D), 35 (C/P) 34 (S/D), 35 (C/P) S10 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1B 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 1H 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 1M 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE IJ1 BZ1 Ba1 SEE PAGE 42 JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) FLOOR NO. 1 WIRE AND COWL WIRE 46 (S/D) 48 (C/P) 46 (S/D) 48 (C/P) LUGGAGE ROOM NO. NO 1 WIRE AND FLOOR NO. NO 1 WIRE FLOOR NO. NO 1 WIRE AND LUGGAGE ROOM NO. NO 2 WIRE : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION 46 (S/D) BL 48 (C/P) UNDER THE LEFT QUARTER PILLAR 50 (W/G) BQ 50 (W/G) LOWER BACK PANEL CENTER : SPLICE POINTS CODE B9 B10 SEE PAGE 46 (S/D) WIRE HARNESS WITH SPLICE POINTS FLOOR NO. NO 1 WIRE B12 B13 B17 46 (S/D) LUGGAGE ROOM NO. 1 WIRE 46 (S/D) SEE PAGE WIRE HARNESS WITH SPLICE POINTS 46 (S/D) LUGGAGE ROOM NO. 2 WIRE 48 (C/P) FLOOR NO. NO 1 WIRE B28 48 (C/P) LUGGAGE ROOM NO. 1 WIRE B29 48 (C/P) LUGGAGE ROOM NO. 2 WIRE B25 B26 B14 B16 CODE LUGGAGE ROOM NO. 2 WIRE 121 STOP LIGHT (S/D, C/P) 122 STOP LIGHT (W/G) 123 STOP LIGHT (W/G) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 15A STOP 3 1M 10A GAUGE 9 1H 6 1B 2 A N2 A ,N3 R–L G–R G–W C 1 A J1 JUNCTION CONNECTOR B NOISE FILTER (FOR STOP LIGHT) R–L Y 1 B G–R 17 1H C 2 B G–W 6 1M 6 1 C9 REAR LIGHT WARNING LIGHT [COMB. METER] S10 STOP LIGHT SW G–W 3 Y–G 2 17 L2 LIGHT FAILURE SENSOR 7 8 4 + – Y–G DELAY HOLD 11 3 2 4 R G–R 1 2 4 2 B38 W–B C J5 JUNCTION CONNECTOR W–B C BL 124 BQ BR W–B R9 STOP LIGHT LH [REAR COMB. LIGHT LH] R10 STOP LIGHT RH [REAR COMB. LIGHT RH] 1 B38 W–B G–R W–B R8 STOP LIGHT LH [REAR COMB. LIGHT LH] W–B C G–R 6 Bb1 G–R W–B 3 5 Bd2 G–R B36 1 G–R R11 STOP LIGHT RH [REAR COMB. LIGHT RH] 4 Bc2 G–R 4 Bd2 R H10 HIGH MOUNT STOP LIGHT 5 Bc2 G–R R W–B 1 G–R 2 IJ1 SYSTEM OUTLINE CURRENT IS APPLIED AT ALL TIMES THROUGH A STOP FUSE TO TERMINAL 2 OF THE STOP LIGHT SW. WHEN THE IGNITION SW IS TURNED ON, CURRENT FLOWS FROM THE GAUGE FUSE TO TERMINAL 8 OF THE LIGHT FAILURE SENSOR, AND ALSO FLOWS THROUGH THE REAR LIGHT WARNING LIGHT TO TERMINAL 4 OF THE LIGHT FAILURE SENSOR. STOP LIGHT DISCONNECTION WARNING WHEN THE IGNITION SW IS TURNED ON AND THE BRAKE PEDAL IS PRESSED (STOP LIGHT SW ON), IF THE STOP LIGHT CIRCUIT IS OPEN, THE CURRENT FLOWING FROM TERMINALS 7 OF THE LIGHT FAILURE SENSOR TO TERMINALS 1, 2 CHANGES, SO THE LIGHT FAILURE SENSOR DETECTS THE DISCONNECTION AND THE WARNING CIRCUIT OF THE LIGHT FAILURE SENSOR IS ACTIVATED. AS A RESULT, THE CURRENT FLOWS FROM TERMINAL 4 OF THE LIGHT FAILURE SENSOR → TERMINAL 11 → GROUND AND TURNS THE REAR LIGHT WARNING LIGHT ON. BY PRESSING THE BRAKE PEDAL, THE CURRENT FLOWING TO TERMINAL 8 OF THE LIGHT FAILURE SENSOR KEEPS THE WARNING CIRCUIT ON HOLD AND THE WARNING LIGHT ON UNTIL THE IGNITION SW IS TURNED OFF. SERVICE HINTS S10 STOP LIGHT SW 2–1 : CLOSED WITH BRAKE PEDAL DEPRESSED L 2 LIGHT FAILURE SENSOR 1, 2, 7–GROUND : APPROX. 12 VOLTS WITH STOP LIGHT SW ON 4, 8–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 11–GROUND : ALWAYS CONTINUITY : PARTS LOCATION CODE SEE PAGE CODE C9 32 H10 36 (W/G) N2 J1 33 N3 J5 36 (W/G) SEE PAGE L2 CODE SEE PAGE 36 (W/G) R9 36 (W/G) A 33 R10 36 (W/G) B 33 R11 36 (W/G) 36 (W/G) S10 33 R8 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1B 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 1H 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 1M 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) IJ1 42 FLOOR NO. 1 WIRE AND COWL WIRE Bb1 50 (W/G) LUGGAGE ROOM NO. 1 WIRE AND FLOOR NO. 1 WIRE Bc2 50 (W/G) BACK DOOR NO. 1 WIRE AND FLOOR NO. 1 WIRE Bd2 50 (W/G) BACK DOOR NO. 1 WIRE AND BACK DOOR NO. 2 WIRE : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION 46 (S/D) BL 48 (C/P) UNDER THE LEFT QUARTER PILLAR 50 (W/G) BQ 50 (W/G) LOWER BACK PANEL CENTER BR 50 (W/G) BACK DOOR CENTER : SPLICE POINTS CODE B36 SEE PAGE 50 (W/G) WIRE HARNESS WITH SPLICE POINTS FLOOR NO. 1 WIRE CODE B38 SEE PAGE 50 (W/G) WIRE HARNESS WITH SPLICE POINTS BACK DOOR NO. 2 WIRE 125 ILLUMINATION G 5 G 1 TAILLIGHT RELAY 15A TAIL 2 3 8 1B 14 1D 9 3D 20 3C G 4 3C G C G–R 1 G 5 4 B B B G BATTERY 2 2 R5 REAR WINDOW DEFOGGER SW 3 1 1 B 2 A18 ASHTRAY ILLUMINATION I13 INTEGRATION RELAY H7 HAZARD SW 2 FL MAIN 2. 0L C5 CIGARETTE LIGHTER ILLUMINATION 1 C G TO CLOCK 100A ALT G G I9 B F10 A , F10 B , F16 1 A (1MZ–FE) 1 B (5S–FE) G I12 W 4 EF1 21 3D G W 5 3D FUSE BOX 21 3C G 4 1E 20 3D I9 LIGHT CONTROL SW B 2 OFF TAIL I12 B HEAD C12 COMBINATION SW 11 11 3C 11 3D W–B 1 3D IE 126 B B B 2 1D 5 1B 1 1D 8 1L 12 II2 B I16 1 C B 2 4 C C 1 2 1 IN1 G IN1 1 R7 RHEOSTAT 3 J2 JUNCTION CONNECTOR 2 J2 JUNCTION CONNECTOR G3 GLOVE BOX LIGHT 2 G G A E6 ELECTRONIC CONTROLLED TRANSMISSION PATTERN SELECT SW B O5 A/T INDICATOR LIGHT (SHIFT LEVER) A G–W 9 C 5 B (W/O CD PLAYER) G G B 2 G G (W/ CD PLAYER) G G A C11 A/T INDICATOR LIGHT [COMB. METER] G 2 C 10 A B B I16 G4 GLOVE BOX SW A ,R4 G 10 IM2 B HEATER CONTROL SW A (PUSH SW TYPE) (LEVER SW TYPE) A/C SW B (PUSH SW TYPE) (LEVER SW TYPE) G I14 B (W/O CD PLAYER) (W/ CD PLAYER) (W/ CD PLAYER) B G G G 16 W–B W–G C ,R3 15 A 3 B W–B I14 (W/O CD PLAYER) H8 A12 8 A 7 B 14 A 4 B RADIO AND PLAYER R2 A BLOWER SW 6 A 6 B B 13 A B6 16 B B B 11 1D (W/ CD PLAYER) B B B A , C9 7 1L W–B B COMBINATION METER C8 G 10 1D G 4 1B II2 G I17 (W/ CD PLAYER) G J2 JUNCTION CONNECTOR A A C 2 1 C 1 2 5 IM1 B B B IF 127 ILLUMINATION SERVICE HINTS TAILLIGHT RELAY 5–3 : CLOSED WITH LIGHT CONTROL SW AT TAIL OR HEAD POSITION (WHEN LIGHT AUTO TURN OFF SYSTEM IS OFF) CLOSED WITH ENGINE RUNNING AND PARKING BRAKE LEVER RELEASED (CANADA) R 7 RHEOSTAT 3–2 : APPROX. 12 VOLTS WITH RHEOSTAT FULLY TURNED COUNTERCLOCKWISE AND 0 VOLTS WITH FULLY TURNED CLOCKWISE : PARTS LOCATION CODE A12 SEE PAGE B A18 B6 CODE 32 32 A 32 B 32 C5 SEE PAGE E6 F10 F16 CODE 32 SEE PAGE J2 33 A 28 (1MZ–FE), 30 (5S–FE) B 28 (1MZ–FE), 30 (5S–FE) R2 C 33 C 28 (1MZ–FE), 30 (5S–FE) R3 A 33 R4 B 33 32 G3 33 O5 33 C8 A 32 G4 33 R5 33 C9 B 32 H7 33 R7 33 C11 32 C12 H8 32 A I13 33 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1B 1D 1E 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 24 COWL WIRE AND J/B NO NO. 3 (BEHIND COMBINATION METER) 1L 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE EF1 II2 IM1 IM2 IN1 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ENGINE WIRE AND COWL WIRE 42 INSTRUMENT PANEL WIRE AND COWL WIRE 42 INSTRUMENT PANEL WIRE AND CONSOLE BOX WIRE 42 INSTRUMENT PANEL WIRE AND SWITCH WIRE : GROUND POINTS CODE IE IF SEE PAGE 42 GROUND POINTS LOCATION LEFT KICK PANEL : SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS I9 I12 I14 128 CODE I16 44 COWL WIRE I17 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS INSTRUMENT PANEL WIRE 129 INTERIOR LIGHT (S/D, C/P w/ KEY ILLUMINATED ENTRY) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 20A DOME R 2 2G 1 1C 5 1C R 12 1K R II2 R 3 A J3 JUNCTION CONNECTOR 14 3C INTEGRATION RELAY A R 1 R–B 14 3D 16 IH2 R I11 IGNITION KEY CYLINDER LIGHT (* 2) R–Y 3 D7 DIODE (FOR COURTESY) I8 6 10 2 1B 15 1K 8 II2 G–R 7 1K R–G 6 II2 R–W 9 1K R–Y 2 II2 R–Y 1 1K 1 2 DIODE R–Y 1 R–Y W–B G–R R–G R–W R–W R–W 2 R–B 4 G–R IJ1 3 1B II2 2 (* 2) R 17 15 I8 2 IJ1 R–L W–B 11 IH1 1 (* 2) R–Y 15 1 G–R 4 C9 OPEN DOOR WARNING LIGHT [COMB. METER] 2 (*1)(S/D) R–B 3 4 5 D16 DOOR KEY CYLINDER LIGHT AND SW 9 IH1 FROM DOOR LOCK CONTROL RELAY 10 IH1 R R 16 3A 2 1H 19 1H 1 1M 130 B IF 1 W–B D14 DOOR COURTESY SW REAR LH R–W 1 W–B D15 DOOR COURTESY SW REAR RH R–Y D13 DOOR COURTESY SW FRONT RH 1 J1 JUNCTION CONNECTOR 16 IU1 IU1 R–W 6 D12 DOOR COURTESY SW FRONT LH R–G B 1 IG W–B BK R–W 1 2 R 1 L3 LUGGAGE COMPARTMENT LIGHT R 2 R–Y W–B V9 VANITY LIGHT RH R R (* 1)(S/D) (* 2) R B 4 : S/D B20 : C/P R–W (* 2) W–B W–B 1 (C/P) 6 R (*2) 1I (S/D) 1I 6 (*2) W–B W–B V8 VANITY LIGHT LH R 1 (* 1)(S/D) B 5 : S/D B20 : C/P R (W/ MOON ROOF) OFF ON DOOR I14 INTERIOR LIGHT B 4 : S/D B20 : C/P W–B RH (* 2) R–W 1 (W/ MOON ROOF) LH 4 M3 PERSONAL LIGHT R–W IV2 (* 1)(S/D) (* 2) 4 R–W * 1 : TMC MADE * 2 : TMM MADE 6 1H IV2 R 1 2 2 IV2 1I 1 5 1M 5 BZ1 4 1 L4 LUGGAGE COMPARTMENT LIGHT SW IE 131 INTERIOR LIGHT (S/D, C/P w/ KEY ILLUMINATED ENTRY) * 1 : TMC MADE * 2 : TMM MADE SERVICE HINTS INTEGRATION RELAY 4–GROUND : APPROX. 12 VOLTS WITH DOOR CLOSED 0 VOLTS WITH EACH DOOR OPEN D12, D13, D14, D15 DOOR COURTESY SW 1–GROUND : CLOSED WITH DOOR OPEN L 4 LUGGAGE COMPARTMENT LIGHT SW 1–GROUND : CLOSED WITH LUGGAGE COMPARTMENT DOOR OPEN : PARTS LOCATION CODE SEE PAGE C9 32 CODE SEE PAGE CODE SEE PAGE D16 34 (S/D), 35 (C/P) L4 34 (S/D), 35 (C/P) D7 32 I11 33 M3 34 (S/D), 35 (C/P) D12 34 (S/D), 35 (C/P) I14 34 (S/D), 35 (C/P) V8 34 (S/D), 35 (C/P) D13 34 (S/D), 35 (C/P) J1 33 V9 34 (S/D), 35 (C/P) D14 34 (S/D), 35 (C/P) J3 33 D15 34 (S/D), 35 (C/P) L3 34 (S/D), 35 (C/P) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1B 1C 1H 1I 1K 1M 2G SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 20 (*1) ROOF WIRE AND J/B NO. 1 (INSTRUMENT PANEL) TMC MADE 20 (*2) COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL) TMM MADE 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO. 3 (BEHIND COMBINATION METER) 3A 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE IH1 IH2 SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) 42 FRONT DOOR LH WIRE AND INSTRUMENT PANEL WIRE II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE IJ1 42 FLOOR NO. 1 WIRE AND COWL WIRE IU1 44 FLOOR NO. 2 WIRE AND INSTRUMENT PANEL WIRE IV2 44 ROOF WIRE AND COWL WIRE MADE IN USA BZ1 46 (S/D) 48 (C/P) LUGGAGE ROOM NO. NO 1 WIRE AND FLOOR NO. NO 1 WIRE : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION IF 42 LEFT KICK PANEL IG 42 INSTRUMENT PANEL BRACE LH BK 46 (S/D) 48 (C/P) ROOF LEFT : SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS CODE SEE PAGE I8 44 INSTRUMENT PANEL WIRE B5 46 (S/D) B4 46 (S/D) ROOF WIRE B20 48 (C/P) 132 WIRE HARNESS WITH SPLICE POINTS ROOF WIRE 133 INTERIOR LIGHT (W/G w/ KEY ILLUMINATED ENTRY) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 20A DOME R 2 2G 1 1C R 1 Bc2 R II2 R 3 5 1C R 6 1H R 12 1K A 1 J3 JUNCTION CONNECTOR R 14 3C L3 LUGGAGE COMPARTMENT LIGHT A R–B 16 3A 14 3D 134 R–Y G–R R–Y D9 DIODE (FOR COURTESY) 2 1B 15 G–R 6 II2 R–W 9 1K 2 II2 R–Y 1 1K 7 1K 1 2 DIODE 19 1H R–W L4 LUGGAGE COMPARTMENT LIGHT SW R–W 1 IF IJ1 BR B34 D14 DOOR COURTESY SW REAR LH R–W 1 B W–B D15 DOOR COURTESY SW REAR RH R–Y 1 J2 JUNCTION CONNECTOR 16 IU1 D13 DOOR COURTESY SW FRONT RH R–W IU1 2 R–W 8 II2 2 B 6 1 1K W–B D7 DIODE (FOR COURTESY) R–Y I8 15 2 1 R–B R–Y 1 R–Y II2 W–B G–R R–G R–W R–W R–W 2 4 5 3 15 I8 R–W 16 IH2 2 Bc3 R–W W–B 11 IH1 R–W 1 2 Bd2 R–W R–B 4 D16 DOOR KEY CYLINDER LIGHT AND SW R 2 FROM DOOR LOCK CONTROL RELAY 3 G–R B38 I11 IGNITION KEY CYLINDER LIGHT R R 9 IH1 C9 OPEN DOOR WARNING LIGHT [COMB. METER] 10 IH1 R–W 2 1 W–B W–B 4 IG 1I 1 4 1 BP B31 1 2 6 6 (* 1) R 1 W–B 2 V9 VANITY LIGHT RH V8 VANITY LIGHT LH R R 1 (* 1) W–B 1 R 1 (W/ MOON ROOF) OFF ON B33 W–B 4 DOOR R RH 10 LH 4 R–W I14 INTERIOR LIGHT INTEGRATION RELAY W–B 2 1H 2 M3 PERSONAL LIGHT R–W 3 W–B D12 DOOR COURTESY SW FRONT LH R–G * 1 : LE AND GL GRADE IN CANADA II IV1 R (* 1) R (* 1) R 1 IV1 2 B30 IV1 1 1M 1I 5 1M IE 135 INTERIOR LIGHT (W/G w/ KEY ILLUMINATED ENTRY) SERVICE HINTS INTEGRATION RELAY 4–GROUND : APPROX. 12 VOLTS WITH DOOR CLOSED 0 VOLTS WITH EACH DOOR OPEN D12, D13, D14, D15 DOOR COURTESY SW 1–GROUND : CLOSED WITH DOOR OPEN L 4 LUGGAGE COMPARTMENT LIGHT SW 2–1 : CLOSED WITH LUGGAGE COMPARTMENT DOOR OPEN : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE C9 32 D15 36 (W/G) D7 32 D16 D9 36 I11 D12 36 (W/G) D13 D14 CODE SEE PAGE L3 36 (W/G) 36 (W/G) L4 36 (W/G) 33 M3 36 (W/G) I14 36 (W/G) V8 36 (W/G) 36 (W/G) J2 33 V9 36 (W/G) 36 (W/G) J3 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1B 1C 1H 1I 1K 1M 2G SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 20 ROOF WIRE AND J/B NO. 1 (INSTRUMENT PANEL) TMC MADE 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL) TMM MADE 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO. 3 (BEHIND COMBINATION METER) 3A 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE IH1 SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) 42 FRONT DOOR LH WIRE AND INSTRUMENT PANEL WIRE II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE IJ1 42 FLOOR NO. 1 WIRE AND COWL WIRE 44 FRONT DOOR RH WIRE AND INSTRUMENT PANEL WIRE IU1 44 FLOOR NO. 2 WIRE AND INSTRUMENT PANEL WIRE IV1 44 ROOF WIRE AND COWL WIRE 50 (W/G) BACK DOOR NO. NO 1 WIRE AND FLOOR NO. NO 1 WIRE 50 (W/G) BACK DOOR NO. 1 WIRE AND BACK DOOR NO. 2 WIRE IH2 IT1 IT2 Bc2 Bc3 Bd2 : GROUND POINTS CODE IE IF SEE PAGE GROUND POINTS LOCATION 42 LEFT KICK PANEL IG 42 INSTRUMENT PANEL BRACE LH BP 50 (W/G) BACK PANEL CENTER BR 50 (W/G) BACK DOOR CENTER : SPLICE POINTS CODE I8 B30 B31 136 SEE PAGE 44 50 (W/G) WIRE HARNESS WITH SPLICE POINTS INSTRUMENT PANEL WIRE ROOF WIRE CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS B33 50 (W/G) ROOF WIRE B39 50 (W/G) ROOF WIRE NO. 1 WIRE 137 1 138 1 IJ1 3 R–L 6 1K 2 II2 R–Y 1 1K 1 19 1H 1 2 1H B7 1 IG 3 DIODE R–L IV2 R–W 2 1B R 1 (W/ MOON ROOF) (* 2) R–W L3 LUGGAGE COMPARTMENT LIGHT OFF ON 2 4 BK 1 R–Y(C/P) 1B DOOR R R R R (* 2) R (* 2) R (* 1)(S/D) R 6 1H R–W(S/D) R–W 2 RH 6 II2 B 4 : S/D B20 : C/P L4 LUGGAGE COMPARTMENT LIGHT SW (* 2) 10 (* 1)(S/D) 1 I14 INTERIOR LIGHT R 1 LH R–Y G–R I11 IGNITION KEY CYLINDER LIGHT INTEGRATION RELAY (W/ MOON ROOF) IU1 (* 2) R–Y R 5 1C M3 PERSONAL LIGHT D7 DIODE (FOR COURTESY) 7 IJ1 W–B 16 I8 R 15 (* 2) 5 2 W–B R C9 OPEN DOOR WARNING LIGHT [COMB. METER] 4 R–G 1 R–Y (* 1)(S/D) FROM DOOR LOCK CONTROL RELAY 14 3D R–W R–Y R–G R–W 14 3C D12 DOOR COURTESY SW FRONT LH IU1 10 3A D14 DOOR COURTESY SW REAR LH R–W R–Y 6 R–W 2 D15 DOOR COURTESY SW REAR RH R–W I8 D13 DOOR COURTESY SW FRONT RH R–W R INTERIOR LIGHT (S/D, C/P w/o KEY ILLUMINATED ENTRY) * 1 : TMC MADE * 2 : TMM MADE FROM POWER SOURCE SYSTEM (SEE PAGE 64) 20A DOME 2 2G 1 1C R 1 1I 1 1V2 1 2 3 1I R–W (* 2) 2 1 1M 1 5 BZ1 * 1 : TMC MADE * 2 : TMM MADE SERVICE HINTS INTEGRATION RELAY 6–GROUND : APPROX. 12 VOLTS WITH DOOR CLOSED 0 VOLTS WITH EACH DOOR OPEN D12, D13, D14, D15 DOOR COURTESY SW 1–GROUND : CLOSED WITH DOOR OPEN L 4 LUGGAGE COMPARTMENT LIGHT SW 1–GROUND : CLOSED WITH LUGGAGE COMPARTMENT DOOR OPEN : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE CODE SEE PAGE C9 32 D14 34 (S/D), 35 (C/P) J3 33 D7 32 D15 34 (S/D), 35 (C/P) L3 34 (S/D), 35 (C/P) D12 34 (S/D), 35 (C/P) I11 33 L4 34 (S/D), 35 (C/P) D13 34 (S/D), 35 (C/P) I14 34 (S/D), 35 (C/P) M3 34 (S/D), 35 (C/P) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1B 1C 1H 1I 1K 1M 2G SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 20 (*1) ROOF WIRE AND J/B NO. 1 (INSTRUMENT PANEL) TMC MADE 20 (*2) COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL) TMM MADE 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO. 3 (BEHIND COMBINATION METER) 3A 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE IJ1 42 FLOOR NO. 1 WIRE AND COWL WIRE IU1 44 FLOOR NO. 2 WIRE AND INSTRUMENT PANEL WIRE IV2 44 ROOF WIRE AND COWL WIRE MADE IN USA BZ1 46 (S/D) LUGGAGE ROOM NO. NO 1 WIRE AND FLOOR NO. NO 1 WIRE 48 (C/P) : GROUND POINTS CODE IG BK SEE PAGE 42 GROUND POINTS LOCATION INSTRUMENT PANEL BRACE LH 46 (S/D) ROOF LEFT 48 (C/P) : SPLICE POINTS CODE SEE PAGE I8 44 B4 46 (S/D) WIRE HARNESS WITH SPLICE POINTS CODE B6 INSTRUMENT PANEL WIRE B7 ROOF WIRE B20 C9 D7 1 X X L3 1 4 5 WIRE HARNESS WITH SPLICE POINTS 46 (S/D) FLOOR NO. NO 1 WIRE 48 (C/P) ROOF WIRE I11 D12, D13, D14, D15 1 1 L4 2 2 BLACK SEE PAGE 1 GRAY 2 BLUE I14 1 2 M3 1 4 139 INTERIOR LIGHT (W/G w/o KEY ILLUMINATED ENTRY) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 20A DOME R 2 2G 1 1C 5 1C R R 6 1H 14 3C R–W 1 Bc2 L3 LUGGAGE COMPARTMENT LIGHT R I11 IGNITION KEY CYLINDER LIGHT 1 4 C9 OPEN DOOR WARNING LIGHT [COMB. METER] 2 R–Y 2 Bc3 R–Y G–R R–W 3 FROM DOOR LOCK CONTROL RELAY R–W 1 5 R–W 2 B39 14 3D R 16 3A D9 DIODE (FOR COURTESY) 15 2 IJ1 2 1B R–W R–G 1 6 II2 I8 R–W 2 1 R–Y I8 R–Y 2 II2 1K 1 1K R–Y 1 2 DIODE 19 1H 2 1H R–W R–Y R–W D7 DIODE (FOR COURTESY) R–W 9 R–L R–W R–W 2 Bd2 B35 R–W R–G 1 L4 LUGGAGE COMPARTMENT LIGHT SW 1 1 1 W–B 1 D13 DOOR COURTESY SW FRONT RH 140 2 16 IU1 R–Y IU1 R–W 6 D15 DOOR COURTESY SW REAR RH BR D14 DOOR COURTESY SW REAR LH D12 DOOR COURTESY SW FRONT LH 1I R 1 IV1 R 1 INTEGRATION RELAY B33 R 1 R (W/ MOON ROOF) M3 PERSONAL LIGHT LH R–W 1 RH 10 4 3 3 1I IV1 R–W IG W–B (W/ MOON ROOF) 1 1M W–B 2 DOOR I14 INTERIOR LIGHT 1 OFF ON 2 BP 141 INTERIOR LIGHT (W/G w/o KEY ILLUMINATED ENTRY) SERVICE HINTS INTEGRATION RELAY 6–GROUND : APPROX. 12 VOLTS WITH DOOR CLOSED 0 VOLTS WITH EACH DOOR OPEN D12, D13, D14, D15 DOOR COURTESY SW 1–GROUND : CLOSED WITH DOOR OPEN L 4 LUGGAGE COMPARTMENT LIGHT SW 2–1 : CLOSED WITH LUGGAGE COMPARTMENT DOOR OPEN : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE C9 32 D14 36 (W/G) D7 32 D15 D9 36 (W/G) I11 D12 36 (W/G) I14 36 (W/G) D13 36 (W/G) J3 33 CODE SEE PAGE L3 36 (W/G) 36 (W/G) L4 36 (W/G) 33 M3 36 (W/G) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1B 1C 1H 1I 1K 1M 2E SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 20 ROOF WIRE AND J/B NO. 1 (INSTRUMENT PANEL) TMC MADE 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL) TMM MADE 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 22 ENGINE ROOM MAIN WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO. 3 (BEHIND COMBINATION METER) 3A 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE IH1 SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) 42 FRONT DOOR LH WIRE AND INSTRUMENT PANEL WIRE II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE IJ1 42 FLOOR NO. 1 WIRE AND COWL WIRE 44 FRONT DOOR RH WIRE AND INSTRUMENT PANEL WIRE IU1 44 FLOOR NO. 2 WIRE AND INSTRUMENT PANEL WIRE IV1 44 ROOF WIRE AND COWL WIRE 50 (W/G) BACK DOOR NO. NO 1 WIRE AND FLOOR NO. NO 1 WIRE 50 (W/G) BACK DOOR NO. 1 WIRE AND BACK DOOR NO. 2 WIRE IH2 IT1 IT2 Bc2 Bc3 Bd2 : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION IG 42 INSTRUMENT PANEL BRACE LH BP 50 (W/G) BACK PANEL CENTER BR 50 (W/G) BACK DOOR CENTER : SPLICE POINTS CODE I8 B33 142 SEE PAGE WIRE HARNESS WITH SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS 44 INSTRUMENT PANEL WIRE B35 50 (W/G) FLOOR NO. 1 WIRE 50 (W/G) ROOF WIRE B39 50 (W/G) BACK DOOR NO. 1 WIRE 143 TAILLIGHT (S/D, C/P) 1 5 TAILLIGHT RELAY 2 4 1E 15A TAIL 3 7 1H 12 BZ1 G G 8 1B G W 14 1D 4 EF1 G 100A ALT G 3 ED1 1 C B F10 A , F10 B , F16 1 A (1MZ–FE) 1 B (5S–FE) FUSE BOX 4 3D G–R C W 5 3D E4 2 G I13 INTEGRATION RELAY G FL MAIN 2. 0L 1 E4 IE W–B W–B E4 EB 2 W–B E4 EA G 1 2 W–B G G 2 F6 FRONT SIDE MARKER RH 2 1 W–B 11 W–B C12 COMBINATION SW 1 W–B HEAD 1 F4 FRONT CLEARANCE LIGHT RH TAIL W–B F3 FRONT CLEARANCE LIGHT LH LIGHT CONTROL SW 2 OFF F5 FRONT SIDE MARKER LH G BATTERY 144 G G E4 FROM POWER SOURCE SYSTEM (SEE PAGE 64) B12 : S/D B28 : C/P 10A GAUGE G 6 1B G J1 JUNCTION CONNECTOR R–L C C R–L 6 C9 REAR LIGHT WARNING LIGHT [COMB. METER] Y 9 1H Y–G 3 2 BZ1 IJ1 Y Y–G 17 3 BZ1 3 8 – + 11 LG 9 B12 : S/D B28 : C/P LG 13 BZ1 LG 2 Ba1 LG B16 : S/D B29 : C/P LG B13 : S/D B28 : C/P Y–G DELAY CIRCUIT W–B G L2 LIGHT FAILURE SENSOR 4 3 W–B R9 TAILLIGHT LH [REAR COMB. LIGHT LH] 3 1 W–B B14 : S/D B28 : C/P W–B B15 : S/D B28 : C/P W–B R8 REAR COMBINATION LIGHT LH W–B 5 1 W–B W–B R10 REAR COMBINATION LIGHT RH R11 TAILLIGHT RH [REAR COMB. LIGHT RH] 5 4 TAILLIGHT LH TAILLIGHT RH 2 6 W–B LG 4 REAR SIDE MARKER LH G 6 REAR SIDE MARKER RH 1 W–B L1 LICENSE PLATE LIGHT G LG G LG LG LG B13 : S/D B28 : C/P B16 : S/D B29 : C/P 7 BZ1 W–B W–B W–B 4 Ba1 W–B B 9 : S/D B25 : C/P W–B BL W–B BO 145 TAILLIGHT (S/D, C/P) SYSTEM OUTLINE WHEN THE LIGHT CONTROL SW IS TURNED TO TAIL OR HEAD POSITION, THE CURRENT FLOWS TO TERMINAL 3 OF THE LIGHT FAILURE SENSOR THROUGH THE TAIL FUSE. WHEN THE IGNITION SW IS TURNED ON, THE CURRENT FLOWS FROM THE GAUGE FUSE TO TERMINAL 8 OF THE LIGHT FAILURE SENSOR, AND ALSO FLOWS THROUGH THE REAR LIGHTS WARNING LIGHT TO TERMINAL 4 OF THE LIGHT FAILURE SENSOR. TAILLIGHT DISCONNECTION WARNING WHEN THE IGNITION SW ON AND THE LIGHT CONTROL SW TURNED TO TAIL OR HEAD POSITION, IF THE TAILLIGHT CIRCUIT IS OPEN, THE LIGHT FAILURE SENSOR DETECTS THE FAILURE BY THE CHANGE IN CURRENT FLOWING FROM TERMINAL 3 OF THE LIGHT FAILURE SENSOR TO TERMINAL 9 AND THE WARNING CIRCUIT OF THE LIGHT FAILURE SENSOR IS ACTIVATED. AS A RESULT, THE CURRENT FLOWS FLOM TERMINAL 4 OF THE LIGHT FAILURE SENSOR → TERMINAL 11 → GROUND AND TURNS THE REAR LIGHT WARNING LIGHT ON, WHICH REMAINS ON UNTIL THE LIGHT CONTROL SW IS TURNED OFF. SERVICE HINTS TAILLIGHT RELAY 1–4 : CLOSED WITH LIGHT CONTROL SW AT TAIL OR HEAD POSITION L 2 LIGHT FAILURE SENSOR 4, 8–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 3–GROUND : APPROX 12 VOLTS WITH LIGHT CONTROL SW AT TAIL OR HEAD POSITION 11–GROUND : ALWAYS CONTINUITY : PARTS LOCATION CODE SEE PAGE C9 32 C12 32 D4 32 F3 28 (1MZ–FE), 30 (5S–FE) F4 28 (1MZ–FE), 30 (5S–FE) F5 28 (1MZ–FE), 30 (5S–FE) CODE SEE PAGE F6 28 (1MZ–FE), 30 (5S–FE) SEE PAGE 28 (1MZ–FE), 30 (5S–FE) L2 34 (S/D), 35 (C/P) 28 (1MZ–FE), 30 (5S–FE) R8 34 (S/D), 35 (C/P) C 28 (1MZ–FE), 30 (5S–FE) R9 34 (S/D), 35 (C/P) I13 33 R10 34 (S/D), 35 (C/P) J1 33 R11 34 (S/D), 35 (C/P) F16 JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 1H 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 3D 24 COWL WIRE AND J/B NO. 3 (BEHIND COMBINATION METER) 1E : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE ED1 EF1 IJ1 BZ1 Ba1 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) 42 JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) COWL WIRE AND ENGINE ROOM MAIN WIRE ENGINE WIRE AND COWL WIRE FLOOR NO. 1 WIRE AND COWL WIRE 46 (S/D) 48 (C/P) 46 (S/D) 46 (S/D) LUGGAGE ROOM NO. NO 1 WIRE AND FLOOR NO. NO 1 WIRE FLOOR NO. NO 1 WIRE AND LUGGAGE ROOM NO. NO 2 WIRE : GROUND POINTS CODE EA EB IE SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) 42 GROUND POINTS LOCATION FRONT RIGHT FENDER FRONT LEFT FENDER LEFT KICK PANEL 46 (S/D) BL 48 (C/P) UNDER THE LEFT QUARTER PILLAR 50 (W/G) BQ 146 50 (W/G) 34 (S/D), 35 (C/P) B 1B 1D SEE PAGE L1 A F10 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE CODE LOWER BACK PANEL CENTER : SPLICE POINTS CODE E4 B9 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 46 (S/D) WIRE HARNESS WITH SPLICE POINTS ENGINE ROOM MAIN WIRE FLOOR NO. 1 WIRE B12 B13 46 (S/D) LUGGAGE ROOM NO. 1 WIRE CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS B15 46 (S/D) LUGGAGE ROOM NO. 1 WIRE B16 46 (S/D) LUGGAGE ROOM NO. 2 WIRE B25 48 (C/P) FLOOR NO. 1 WIRE B28 48 (C/P) LUGGAGE ROOM NO. 1 WIRE B29 48 (C/P) LUGGAGE ROOM NO. 2 WIRE B14 147 TAILLIGHT (W/G) 1 5 TAILLIGHT RELAY 2 4 1E 15A TAIL 3 7 1H G 8 1B G W 14 1D 4 EF1 C W 5 3D 100A ALT G G–R 4 3D G 3 ED1 1 C B FUSE BOX F10 A , F10 B , F16 1 A (1MZ–FE) 1 B (5S–FE) E4 2 G I13 INTEGRATION RELAY G FL MAIN 2. 0L 1 E4 G E4 IE 148 W–B W–B E4 EB 2 W–B E4 EA G 1 2 W–B G G 2 F6 FRONT SIDE MARKER RH 2 1 W–B 11 W–B C12 COMBINATION SW 1 W–B HEAD 1 F4 FRONT CLEARANCE LIGHT RH TAIL W–B F3 FRONT CLEARANCE LIGHT LH LIGHT CONTROL SW 2 OFF F5 FRONT SIDE MARKER LH G G BATTERY FROM POWER SOURCE SYSTEM (SEE PAGE 64) 10A GAUGE G 6 1B G B37 J1 JUNCTION CONNECTOR C R–L C R–L 9 1H 6 Y G C9 REAR LIGHT WARNING LIGHT [COMB. METER] Y–G 3 IJ1 Y–G 17 3 8 4 G L2 LIGHT FAILURE SENSOR 2 Bc2 1 Bd2 – + DELAY CIRCUIT 11 LG 3 Bc2 LG 6 Bd2 LG B38 LG B36 W–B LG 9 7 LG B36 3 1 4 LG R9 TAILLIGHT LH [REAR COMB. LIGHT LH] R11 TAILLIGHT RH [REAR COMB. LIGHT RH] 3 2 W–B 2 R8 TAILLIGHT LH [REAR COMB. LIGHT LH] 1 R10 TAILLIGHT RH [REAR COMB. LIGHT RH] 2 1 4 C J5 JUNCTION CONNECTOR C W–B BQ BL W–B W–B W–B W–B C W–B L1 LICENSE PLATE LIGHT LG LG LG G Bb1 BR 149 TAILLIGHT (W/G) SYSTEM OUTLINE WHEN THE LIGHT CONTROL SW IS TURNED TO TAIL OR HEAD POSITION, THE CURRENT FLOWS TO TERMINAL 3 OF THE LIGHT FAILURE SENSOR THROUGH THE TAIL FUSE. WHEN THE IGNITION SW IS TURNED ON, THE CURRENT FLOWS FROM THE GAUGE FUSE TO TERMINAL 8 OF THE LIGHT FAILURE SENSOR, AND ALSO FLOWS THROUGH THE REAR LIGHTS WARNING LIGHT TO TERMINAL 4 OF THE LIGHT FAILURE SENSOR. TAILLIGHT DISCONNECTION WARNING WITH THE IGNITION SW ON AND THE LIGHT CONTROL SW TURNED TO TAIL OR HEAD POSITION, IF THE TAILLIGHT CIRCUIT IS OPEN, THE LIGHT FAILURE SENSOR DETECTS THE FAILURE BY THE CHANGE IN CURRENT FLOWING FROM TERMINAL 3 OF THE LIGHT FAILURE SENSOR TO TERMINAL 9 AND THE WARNING CIRCUIT OF THE LIGHT FAILURE SENSOR IS ACTIVATED. AS A RESULT, THE CURRENT FLOWS FROM TERMINAL 4 OF THE LIGHT FAILURE SENSOR → TERMINAL 11 → GROUND AND TURNS THE REAR LIGHT WARNING LIGHT ON, WHICH REMAINS ON UNTIL THE LIGHT CONTROL SW IS TURNED OFF. SERVICE HINTS TAILLIGHT RELAY 3–5 : CLOSED WITH LIGHT CONTROL SW AT TAIL OR HEAD POSITION L 2 LIGHT FAILURE SENSOR 4, 8–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 3–GROUND : APPROX 12 VOLTS WITH LIGHT CONTROL SW AT TAIL OR HEAD POSITION 11–GROUND : ALWAYS CONTINUITY : PARTS LOCATION CODE SEE PAGE C9 32 C12 32 F3 28 (1MZ–FE), 30 (5S–FE) F4 28 (1MZ–FE), 30 (5S–FE) F5 F6 CODE SEE PAGE B C 28 (1MZ–FE), 30 (5S–FE) L2 36 (W/G) 28 (1MZ–FE), 30 (5S–FE) R8 36 (W/G) I13 33 R9 36 (W/G) 28 (1MZ–FE), 30 (5S–FE) J1 33 R10 36 (W/G) 28 (1MZ–FE), 30 (5S–FE) J5 36 (W/G) R11 36 (W/G) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1B 1D 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 1H 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 3D 24 COWL WIRE AND J/B NO. 3 (BEHIND COMBINATION METER) 1E : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE ED1 EF1 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) COWL WIRE AND ENGINE ROOM MAIN WIRE ENGINE WIRE AND COWL WIRE IJ1 42 FLOOR NO. 1 WIRE AND COWL WIRE Bb1 50 (W/G) LUGGAGE ROOM NO. 1 WIRE AND FLOOR NO. 1 WIRE Bc2 50 (W/G) BACK DOOR NO. 1 WIRE AND FLOOR NO. 1 WIRE Bd2 50 (W/G) BACK DOOR NO. 1 WIRE AND BACK DOOR NO. 2 WIRE : GROUND POINTS CODE EA EB IE SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) 42 GROUND POINTS LOCATION FRONT RIGHT FENDER FRONT LEFT FENDER LEFT KICK PANEL 46 (S/D) BL 48 (C/P) UNDER THE LEFT QUARTER PILLAR 50 (W/G) BQ 50 (W/G) LOWER BACK PANEL CENTER BR 50 (W/G) BACK DOOR CENTER 150 SEE PAGE 36 (W/G) F16 28 (1MZ–FE), 30 (5S–FE) CODE L1 F10 A : SPLICE POINTS CODE E4 B36 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 50 (W/G) WIRE HARNESS WITH SPLICE POINTS ENGINE ROOM MAIN WIRE CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS B37 50 (W/G) FLOOR NO. 1 WIRE B38 50 (W/G) BACK DOOR NO. 2 WIRE FLOOR NO. 1 WIRE 151 BACK–UP LIGHT FROM POWER SOURCE SYSTEM (SEE PAGE 64) 10A GAUGE R–L 6 1D IP3 R–L R–L R–L R–L I18 (A/T) 2 (M/T) TO VEHICLE SPEED SENSOR (SPEED SENSOR) TO GENERATOR (ALTERNATOR) 2 B1 BACK–UP LIGHT SW R–B 8 (A/T) P1 BACK–UP LIGHT SW [PARK/NEUTRAL POSITION SW (NEUTRAL START SW)] R–B 1 (M/T) IP3 R–B 1 R–L I18 (A/T) TO VEHICLE SPEED SENSOR (SPEED SENSOR) TO GENERATOR (ALTERNATOR) (A/T) R–L (M/T) (M/T) 2 R–B R–B 6 Bc2 3 Ba1 R–B R–B 3 Bd2 (S/D, C/P) R–B IJ1 (W/G) 10 R–B B38 (W/G) R–B R–B (W/G) B16 (S/D, W/G) R–B (S/D, C/P) 4 A (S/D, C/P) 3 B (W/G) R9 4 A (S/D, C/P) 3 B (W/G) A , B R11 BACK–UP LIGHT LH [REAR COMB. LIGHT LH] 3 A (S/D, C/P) 4 B (W/G) A , B BACK–UP LIGHT RH [REAR COMB. LIGHT RH] 3 A (S/D, C/P) 4 B (W/G) W–B (S/D, C/P) W–B W–B B16 BR 152 W–B 4 Ba1 W–B (W/G) W–B (W/G) (S/D, C/P) BL SERVICE HINTS B 1 BACK–UP LIGHT SW 2–1 : CLOSED WITH SHIFT LEVER IN R POSITION P 1 BACK–UP LIGHT SW [PARK/NEUTRAL POSITION SW (NEUTRAL START SW)] 6–5 : CLOSED WITH SHIFT LEVER IN R POSITION : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE CODE B1 30 R9 34 (S/D), 35 (C/P), 36 (W/G) P1 29 (1MZ–FE), 31 (5S–FE) R11 34 (S/D), 35 (C/P), 36 (W/G) SEE PAGE : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1D SEE PAGE 20 JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) IJ1 42 FLOOR NO. 1 WIRE AND COWL WIRE IP3 44 ENGINE WIRE AND COWL WIRE Ba1 46 (S/D) 48 (C/P) FLOOR NO. NO 1 WIRE AND LUGGAGE ROOM NO. NO 2 WIRE Bc2 50 (W/G) BACK DOOR NO. 1 WIRE AND FLOOR NO. 1 WIRE Bd2 50 (W/G) BACK DOOR NO. 1 WIRE AND BACK DOOR NO. 2 WIRE : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION 46 (S/D) BL 48 (C/P) UNDER THE LEFT QUARTER PILLAR 50 (W/G) BR 50 (W/G) BACK DOOR CENTER : SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS I18 44 ENGINE WIRE B16 46 (S/D) LUGGAGE ROOM NO. 2 WIRE B1 B38 GRAY P1 X 1 2 CODE GRAY SEE PAGE WIRE HARNESS WITH SPLICE POINTS 50 (W/G) R9 BACK DOOR NO. 2 WIRE A , B , R11 A , B 2 8 3 4 153 REMOTE CONTROL MIRROR * 1 : TMC MADE * 2 : TMM MADE FROM POWER SOURCE SYSTEM (SEE PAGE 64) 15A CIG/RADIO L–R 9 1L II2 L–R 9 B J3 JUNCTION CONNECTOR L–R B RIGHT UP SELECT SW LEFT UP 5 2 W–B 3 LG–R 6 RH LG–B 7 BR–Y BR–W LH LG RH 1 DOWN UP RIGHT LEFT LH OPERATION SW R6 REMOTE CONTROL MIRROR SW 8 B J2 JUNCTION CONNECTOR R20 A , B REMOTE CONTROL MIRROR LH 154 LG–R LG 8 IT2 1 A 3 B 3 A 1 B M M R21 7 B IT2 W–B M IT2 LG–R M 2 A (* 1, EX. C/P) 2 B (* 2) 6 LG 3 A 1 B IH1 LG–B 1 A 3 B 5 LG–R 4 IH1 BR–W IH1 BR–Y 6 LG–R BR–Y I4 2 A (* 1, EX. C/P) 2 B (* 2) A , B REMOTE CONTROL MIRROR RH IF SERVICE HINTS R 6 REMOTE CONTROL MIRROR SW 8–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ACC OR ON POSITION 5–2 : CONTINUITY WITH OPERATION SW AT UP OR LEFT POSITION 5–8 : CONTINUITY WITH OPERATION SW AT DOWN OR RIGHT POSITION : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE J2 33 R6 33 J3 33 R20 34 (S/D), 35 (C/P), 36 (W/G) CODE R21 SEE PAGE 34 (S/D), 35 (C/P), 36 (W/G) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1L SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) IH1 42 FRONT DOOR LH WIRE AND INSTRUMENT PANEL WIRE II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE IT2 44 FRONT DOOR RH WIRE AND INSTRUMENT PANEL WIRE : GROUND POINTS CODE IF SEE PAGE GROUND POINTS LOCATION 42 LEFT KICK PANEL : SPLICE POINTS CODE I4 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS INSTRUMENT PANEL WIRE J2 J3 B B B B B B B B B (* 1, EX. C/P) R20 R6 B B B B B 1 2 3 A , R21 A 1 2 3 X 5 6 7 8 B B (HINT : SEE PAGE 7) (HINT : SEE PAGE 7) (* 2) R20 B , R21 B 3 2 1 155 POWER WINDOW FROM POWER SOURCE SYSTEM (SEE PAGE 64) 2 10A GAUGE 8 1K 30A POWER J3 JUNCTION CONNECTOR 4 R–L II2 R–L C 5 R–L C L–R 6 1L 1 D8 DOOR LOCK CONTROL RELAY 1 R–L II2 15 IG 5 1 RLY POWER MAIN RELAY +B 8 2 3 1 1M 11 1K 2 1K L 10 1K W–B 10 II2 L 6 IH2 17 II2 W–L L W–L L B1 L L I3 L L 9 B 7 A (* 1) 8 A (* 2) UP POWER WINDOW MASTER SW DOWN B UP A , DOWN P12 LOCK NORMAL IH2 1 IH2 W–B 156 IF 2 1 M R–L G–W DOWN 2 1 M 2 1 2 1 P13 POWER WINDOW MOTOR FRONT LH IT1 L R–L P14 POWER WINDOW MOTOR FRONT RH (* 2) 4 (* 2) (* 1) (* 1) (* 1) R G (* 2) (* 1) J2 JUNCTION CONNECTOR IG 3 1 B B 2 9 G R G IH2 IT1 R 16 4 5 W–B W–B W–B B1 IT1 G–W 10 (* 2) W–B 13 A (* 2) 4 B (* 1) 6 A 3 B UP 2 A 6 B P9 POWER WINDOW CONTROL SW FRONT RH 1 A W–B L 5 R–L G–W + – 5 A (* 2) 7 B (* 1) 12 A 10 B – + * 1 : C/P * 2 : S/D, W/G L L 7 2 M 1 P16 POWER WINDOW MOTOR REAR RH DOWN L L 13 IG1 5 BW1 2 3 L 6 BW1 (W/G) 7 BW1 R–Y 5 BY1 (S/D) L IG1 R–Y 12 R–B IG1 G–Y 4 DOWN 5 1 4 R 4 G 1 IU1 R UP DOWN 5 IH2 G–B 3 II2 L L 2 2 L 6 BY1 13 L R–B 7 BY1 R–B IU1 G–B 12 G–B IU1 G P11 POWER WINDOW CONTROL SW REAR RH 4 R–B G–B I24 IH2 R–Y L R–Y G–Y IH2 G–Y 12 UP IH2 P10 POWER WINDOW CONTROL SW REAR LH 11 18 9 A (* 2) 10 A R–B 14 A G–B 11 A UP UP DOWN L P12 POWER WINDOW MASTER SW 2 M 1 P15 POWER WINDOW MOTOR REAR LH 157 POWER WINDOW SYSTEM OUTLINE WHEN THE IGNITION SW IS TURNED ON, CURRENT FLOWS THROUGH THE GAUGE FUSE TO TERMINAL 1 OF THE POWER MAIN RELAY → TERMINAL 2 → TO GROUND. THIS ACTIVATES THE RELAY AND THE CURRENT FLOWING TO TERMINAL 5 OF THE RELAY FROM POWER FUSE FLOWS TO TERMINAL 3 OF THE RELAY → TERMINAL 7 OR 8 (EX. C/P), 9 (C/P) OF THE POWER WINDOW MASTER SW → TO TERMINAL 5 OF THE POWER WINDOW SW. 1. MANUAL OPERATION (DRIVER’S WINDOW) WITH THE IGNITION SW TURNED ON AND WITH THE POWER WINDOW MASTER SW (MANUAL SW) IN UP POSITION. THE CURRENT FLOWING TO TERMINAL 7 OR 8 (EX. C/P), 9 (C/P) OF THE POWER WINDOW MASTER SW FLOWS TO TERMINAL 6 (EX. C/P), 3 (C/P) OF THE MASTER SW → TEMINAL 2 OF THE POWER WINDOW MOTOR → TERMINAL 1 → TERMINAL 13 (EX. C/P), 4 (C/P) OF THE MASTER SW → TERMINAL 2 OR 1 (EX. C/P), 6 (C/P) → TO GROUND AND CAUSES THE POWER WINDOW MOTOR TO ROTATE IN THE UP DIRECTION. THE WINDOW ASCENDS ONLY WHILE THE SW IS BEING PUSHED. IN DOWN OPERATION, THE FLOW OF CURRENT FROM TERMINAL 7 OR 8 (EX. C/P), 9 (C/P) OF THE POWER WINDOW MASTER SW TO TERMINAL 13 (EX. C/P), 4 (C/P) OF THE MASTER SW CAUSES THE FLOW OF CURRENT FROM TERMINAL 1 OF THE MOTOR → TERMINAL 2 → TERMINAL 6 (EX. C/P), 3 (C/P) OF THE MASTER SW → TERMINAL 2 OR 1 (EX. C/P), 3 (C/P) → TO GROUND, FLOWING IN THE OPPOSITE DIRECTION TO MANUAL UP OPERATION AND CAUSING THE MOTOR TO ROTATE IN REVERSE LOWERING THE WINDOW. 2. AUTO DOWN OPERATION WITH THE IGNITION SW ON AND WITH THE AUTO SW OF THE POWER WINDOW MASTER SW IN DOWN POSITION, CURRENT FLOWING TO TERMINAL 7 OR 8 OF THE MASTER SW FLOWS TO TERMINAL 13 (EX, C/P), 4 (C/P) OF THE MASTER SW → TERMINAL 1 OF THE POWER WINDOW MOTOR → TERMINAL 2 → TERMINAL 6 (EX. C/P), 3 (C/P) OF THE MASTER SW → TERMINAL 2 (EX. C/P), 6 (C/P) → TO GROUND, CAUSING THE MOTOR TO ROTATE TOWARDS THE DOWN SIDE THEN THE SOLENOID IN THE MASTER SW IS ACTIVATED AND IT LOCKS THE AUTO SW BEING PUSHED, CAUSING THE MOTOR TO CONTINUE TO ROTATE IN AUTO DOWN OPERATION. WHEN THE WINDOW HAS COMPLETELY DESENDED, THE CURRENT FLOW BETWEEN TERMINAL 6 (EX. C/P), 3 (C/P) OF THE MASTER SW AND TERMINAL 2 (EX. C/P), 6 (C/P) INCREASES. AS A RESULT, THE SOLENOID STOPS OPERATING, THE AUTO SW TURNS OFF AND FLOW FROM TERMINAL 7 (EX. C/P), 9 (C/P) OF THE MASTER SW TO TERMINAL 13 (EX. C/P), 4 (C/P) IS CUT OFF, STOPPING THE MOTOR SO THAT AUTO STOP OCCURS. 3. STOPPING OF AUTO DOWN AT DRIVER’S WINDOW HEN THE MANUAL SW (DRIVER’S) IS PUSHED TO THE UP SIDE DURING AUTO DOWN OPERATION, A GROUND CIRCUIT OPENS IN THE MASTER SW AND CURRENT DOES NOT FLOW FROM TERMINAL 6 (EX. C/P), 3 (C/P) OF THE MASTER SW → TO GROUND, SO THE MOTOR STOPS, CAUSING AUTO DOWN OPERATION TO STOP. IF THE MASTER SW IS PUSHED CONTINUOUSLY, THE MOTOR ROTATES IN THE UP DIRECTION IN MANUAL UP OPERATION. 4. MANUAL OPERATION BY POWER WINDOW SW (PASSENGER’S WINDOW) WITH POWER WINDOW SW (PASSENGER’S) PULLED TO THE UP SIDE, CURRENT FLOWING FROM TERMINAL 5 OF THE POWER WINDOW SW FLOWS TO TERMINAL 1 OF THE POWER WINDOW SW → TERMINAL 2 OF THE POWER WINDOW MOTOR → TERMINAL 1 → TERMINAL 4 OF THE POWER WINDOW SW → TERMINAL 3 → TERMINAL 5 (EX. C/P), 7 (C/P) OF THE MASTER SW → TERMINAL 1 OR 2 (EX. C/P), 6 (C/P) → TO GROUND AND CAUSES THE POWER WINDOW MOTOR (PASSENGER’S) TO ROTATE IN THE UP DIRECTION. UP OPERATION CONTINUES ONLY WHILE THE POWER WINDOW SW IS PULLED TO THE UP SIDE. WHEN THE WINDOW DECENDS, THE CURRENT FLOWING TO THE MOTOR FLOWS IN THE OPPOSITE DIRECTION, FROM TERMINAL 1 TO TERMINAL 2, AND THE MOTOR ROTATES IN REVERSE. WHEN THE WINDOW LOCK SW IS PUSHED TO THE LOCK SIDE, THE GROUND CIRCUIT TO THE PASSENGER’S WINDOW BECOMES OPEN. AS A RESULT, EVEN IF OPEN/CLOSE OPERATION OF THE PASSENGER’S WINDOW IS TRIED, THE CURRENT FROM TERMINAL 1 OR 2 (EX. C/P), 6 (C/P) OF THE POWER WINDOW MASTER SW IS NOT GROUNDED AND THE MOTOR DOES NOT ROTATE, SO THE PASSENGER’S WINDOW CAN NOT BE OPERATED AND WINDOW LOCK OCCURS. FURTHERMORE REAR LH RH WINDOW OPERATE THE SAME AS THE ABOVE CIRCUIT. 5. KEY OFF POWER WINDOW OPERATION WITH IGNITION SW TURNED FROM ON TO OFF DOOR LOCK CONTROL RELAY OPERATES AND CURRENT FLOWS FROM POWER FUSE TO TERMINAL 8 OF THE RELAY → TERMINAL 15 → TERMINAL 1 OF POWER MAIN RELAY → TERMINAL 2 → TO GROUND FOR ABOUT 60 SECOND. THE SAME AS NORMAL OPERATION, THE CURRENT FLOWS FROM POWER FUSE → TERMINAL 5 OF THE POWER MAIN RELAY → TERMINAL 3 → TERMINAL 7 OR 8 (EX. C/P), TERMINAL 9 (C/P) OF THE POWER WINDOW MASTER SW AND TERMINAL 3 OF THE POWER MAIN RELAY → TO TERMINAL 5 OF THE POWER WINDOW SW. AS A RESULT, FOR ABOUT 60 SECOND AFTER THE IGNITION SW IS TURNED OFF, THE FUNCTIONING OF THIS RELAY MAKES IT POSSIBLE TO RAISE AND LOWER THE POWER WINDOW. ALSO, BY OPENING THE FRONT DOOR (DOOR OPEN DETECTION SW ON) WITHIN ABOUT 60 SECOND AFTER TURNING THE IGNITION SW TO OFF, A SIGNAL IS INPUT TO DOOR LOCK CONTROL RELAY. AS A RESULT, THE RELAY TURNS OFF AND UP AND DOWN MOVEMENT OF THE POWER WINDOW STOPS. 158 * 1 : C/P * 2 : S/D, W/G SERVICE HINTS P12 POWER WINDOW MASTER SW (C/P) 9–GROUND 6–GROUND 3–GROUND 4–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION : ALWAYS CONTINUITY : APPROX. 12 VOLTS WITH IGNITION SW ON AND MASTER SW (DRIVER’S WINDOW) UP : APPROX. 12 VOLTS WITH IGNITION SW ON AND MASTER SW (DRIVER’S WINDOW) AT DOWN OR AUTO DOWN POSITION P12 POWER WINDOW MASTER SW (EX. C/P) 7, 8–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 1, 2–GROUND : ALWAYS CONTINUITY 6–GROUND : APPROX. 12 VOLTS WITH IGNITION SW ON AND MASTER SW (DRIVER’S WINDOW) UP 13–GROUND : APPROX. 12 VOLTS WITH IGNITION SW ON AND MASTER SW (DRIVER’S WINDOW) AT DOWN OR AUTO DOWN POSITION : PARTS LOCATION CODE SEE PAGE CODE D8 32 P10 J2 33 P11 J3 33 P9 34 (S/D), 35 (C/P), 36 (W/G) P12 SEE PAGE CODE SEE PAGE 34 (S/D), 35 (C/P), 36 (W/G) P13 34 (S/D), 35 (C/P), 36 (W/G) 34 (S/D), 35 (C/P), 36 (W/G) P14 34 (S/D), 35 (C/P), 36 (W/G) A 34 (S/D), 36 (W/G) P15 34 (S/D), 35 (C/P), 36 (W/G) B 35 (C/P) P16 34 (S/D), 35 (C/P), 36 (W/G) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1K 1L 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 1M : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE IG1 SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) 42 FLOOR NO. 1 WIRE AND INSTRUMENT PANEL WIRE 42 FRONT DOOR LH WIRE AND INSTRUMENT PANEL WIRE IT1 44 FRONT DOOR RH WIRE AND INSTRUMENT PANEL WIRE IU1 44 FLOOR NO. 2 WIRE AND INSTRUMENT PANEL WIRE IH1 IH2 BW1 BY1 46 (S/D) 50 (W/G) 46 (S/D) 50 (W/G) REAR DOOR LH WIRE AND FLOOR NO. NO 1 WIRE REAR DOOR RH WIRE AND FLOOR NO. NO 2 WIRE : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION IF 42 LEFT KICK PANEL IG 42 INSTRUMENT PANEL BRACE LH : SPLICE POINTS CODE I3 I24 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS INSTRUMENT PANEL WIRE CODE B1 SEE PAGE 46 (S/D) 50 (W/G) WIRE HARNESS WITH SPLICE POINTS FRONT DOOR LH WIRE 159 DOOR LOCK FROM POWER SOURCE SYSTEM (SEE PAGE 64) 30A POWER 1 5 2 3 POWER MAIN RELAY 6 1L 5 II2 R–L II2 W–L 10 R–L W–L 2 1K L W–B 1 1M 11 1K 8 15 D8 DOOR LOCK CONTROL RELAY LOCK TIMER II2 L 17 6 UNLOCK TIMER IH2 4 5 L–R Y 16 160 IJ L–R Y (* 1) B 7 B 4 A 5 B 2 A 6 IT1 Y IT1 L–B 16 L–R (* 1) L–B M A , D27 L–B D22 DOOR LOCK MOTOR REAR LH L–R 1 2 IT1 6 B (*2) 3 A (*1) M 1 A (*1) 4 B (*2) W–B M W–B B9 BACK DOOR LOCK MOTOR W–B W–B IG 2 8 BW1 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT RH 3 Bd3 (* 1) 1 Bd3 L–B L–R L–B 4 3 BW1 11 (* 1) L–B 4 Bc1 (* 1) L–R 2 Bc1 L–R I3 15 IG1 L–B (* 1) L–R 5 IG1 L–R 16 IG1 L–R 6 IG1 L L–B I3 L–R I3 (W/G) L–B L–B I3 D21 L–B (W/G) L–R L–R B11 : EX. C/P B27 : C/P W–B * 1 : S/D, W/G * 2 : C/P * 3 : W/ POWER WINDOW * 4 : W/ POWER WINDOW, C/P * 5 : W/O POWER WINDOW D8 DOOR LOCK CONTROL RELAY CONTROL CIRCUIT 3 9 6 L L–B L L–R 19 IT1 W–B B B B W–B W–B IF W–B J2 JUNCTION CONNECTOR 16 IH2 W–B W–B W–B 3 IH2 D17 DOOR KEY LOCK AND UNLOCK SW LH L 5 C (* 5) 2 B (* 4) 4 A (* 3) 4 1 1 A 6 B 3 C B 2 : *3 B 1 : *4 B18 : * 5 2 A (* 3) (* 4) (* 5) IH2 L–W LG G IH2 3 LOCK 2 W–B 1 A (* 2) 4 B (* 1) 9 B 8 A 10 W–B M L 6 B (* 2) 3 A (* 1) IH2 1 C 1 B 3 A W–B 5 B 2 A 13 IH2 A , B , C 7 B 4 A 9 L–R IH2 DOOR LOCK CONTROL SW LH D20 M 19 L–W P12 B A , D26 D23 DOOR LOCK MOTOR REAR RH 2 IH2 L–B L–B (* 1) 14 L–B L–R (* 1) L–B LG (* 1) 8 BY1 (* 1) 3 BY1 4 L–R IU1 L–B 15 L–R (* 1) IU1 L–R 5 (* 1) L–R I22 G L–R L–R L–B (* 1) I22 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH L–B UNLOCK L–R SEQURITY W–B W–B W–B B 2 : *3 B 1 : *4 B18 : * 5 B 1 : EX. C/P B18 : C/P 161 * 1 : W/ POWER WINDOW EX. C/P * 2 : W/O POWER WINDOW EX. C/P DOOR LOCK FROM POWER SOURCE SYSTEM (SEE PAGE 64) 10A GAUGE R–L 8 1K II2 R–L 4 C J3 JUNCTION CONNECTOR L–R C D8 DOOR LOCK CONTROL RELAY LG L–W I22 G I22 II2 R–W R–G R–L 19 I22 14 6 II2 14 1K 9 1K 2 1G 2 1H 6 IU1 W–B 5 B (* 2) 3 A (* 1) 1 5 4 A (* 1) 3 B (* 2) 4 1G W–B 1 1M W–B B11 : EX. C/P B27 : C/P IG 162 1 R–W IT1 D13 DOOR COURTESY SW FRONT RH 1 B 2 A 5 D12 DOOR COURTESY SW FRONT LH R–G G W–B 2 D19 A , B DOOR LOCK CONTROL SW RH 3 LOCK 1 IT1 LG 12 LOCK IT1 UNLOCK 1 L–W IT1 D18 DOOR KEY LOCK AND UNLOCK SW RH LG–R UNLOCK 2 I12 UNLOCK WARNING SW [IGNITION SW] W–B R–L L–W L–W 2 R–W LG 7 R–L G 10 LG L–W L G 11 LG 12 G 13 LG–R 1 1 SYSTEM OUTLINE CURRENT ALWAYS FLOWS TO TERMINAL 8 OF THE DOOR LOCK CONTROL RELAY THROUGH THE POWER FUSE. WHEN THE IGNITION SW IS TURNED ON, THE CURRENT FLOWING THROUGH THE GAUGE FUSE FLOWS THROUGH THE COIL SIDE OF THE POWER MAIN RELAY TO GROUND, CAUSING THE RELAY TO OPERATE. THE CURRENT FLOWING THROUGH THE POWER FUSE FLOWS TO THE LH DOOR LOCK CONTROL SW, CAUSING THE INDICATOR LIGHT TO LIGHT UP. 1. MANUAL LOCK OPERATION WHEN THE DOOR LOCK CONTROL SW AND KEY SW ARE PUSHED TO LOCK POSITION, A LOCK SIGNAL IS INPUT TO TERMINAL 10, 12 OF THE DOOR LOCK CONTROL RELAY AND CAUSES THE RELAY TO FUNCTION. CURRENT FLOWS FROM TERMINAL 8 OF THE RELAY → TERMINAL 4 → TERMINAL 4 OF THE DOOR LOCK MOTORS, (EX. C/P FRONT DOOR) OR TERMINAL 7 (C/P FRONT DOOR), OF THE DOOR LOCK MOTOR TERMINAL 2 OF THE BACK DOOR LOCK MOTOR → TERMINAL 2 OF THE DOOR LOCK MOTORS, (EX. C/P FRONT DOOR) OR TERMINAL 5 (C/P FRONT DOOR) OF THE DOOR LOCK MOTOR TERMINAL 1 OF THE BACK DOOR LOCK MOTOR → TERMINAL 3 OF THE RELAY → TERMINAL 16 → TO GROUND AND THE DOOR LOCK MOTOR CAUSES THE DOOR TO LOCK. 2. MANUAL UNLOCK OPERATION WHEN THE DOOR LOCK CONTROL SW AND KEY SW RH TO UNLOCK POSITION, AN UNLOCK SIGNAL IS INPUT TO TERMINAL 11, 13 OF THE DOOR LOCK RELAY AND CAUSES THE RELAY TO FUNCTION. CURRENT FLOWS FROM TERMINAL 8 OF THE RELAY → TERMINAL 3 → TERMINAL 2 OF THE DOOR LOCK MOTORS, (EX. C/P FRONT DOOR) OR TERMINAL 5 (C/P FRONT DOOR) OF THE DOOR LOCK MOTOR TERMINAL 1 OF THE BACK DOOR LOCK MOTOR → TERMINAL 4 OF THE DOOR LOCK MOTORS, (EX. C/P FRONT DOOR) OR TERMINAL 7 (C/P FRONT DOOR), OF THE DOOR LOCK MOTOR TERMINAL 2 OF THE BACK DOOR LOCK MOTOR → TERMINAL 4 OF THE RELAY → TERMINAL 16 → TO GROUND AND DOOR LOCK MOTORS CAUSES DOOR TO UNLOCK. 3. DOUBLE OPERATION UNLOCK OPERATION WHEN THE DOOR LOCK KEY SW (DRIVER’S) IS TURNED TO THE UNLOCK SIDE, ONLY THE DRIVER’S DOOR IS MECHANICALLY UNLOCKED. TURNING THE DOOR LOCK KEY SW (DRIVER’S) TO THE UNLOCK SIDE CAUSES A SIGNAL TO BE INPUT TO TERMINAL 9 OF THE RELAY, AND IF THE SIGNAL IS INPUT AGAIN WITHIN 3 SECONDS BY TURNING THE SW TO THE UNLOCK SIDE AGAIN, CURRENT FLOWS TERMINAL 3 → TERMINAL 2 OF DOOR LOCK MOTORS, (EX. C/P FRONT DOOR) OR TERMINAL 5 (C/P FRONT DOOR) OF THE DOOR LOCK MOTOR TERMINAL 1 OF THE BACK DOOR LOCK MOTOR → TERMINAL 4 OF THE DOOR LOCK MOTORS, (EX. C/P FRONT DOOR) OR TERMINAL 7 (C/P FRONT DOOR), OF THE DOOR LOCK MOTOR TERMINAL 2 OF THE BACK DOOR LOCK MOTOR → TERMINAL 4 OF THE RELAY → TERMINAL 16 → GROUND, CAUSING THE DOOR LOCK MOTORS TO OPERATE AND UNLOCK THE DOORS. 4. IGNITION KEY REMINDER OPERATION * OPERATING DOOR LOCK KNOB (OPERATION OF DOOR LOCK MOTORS) WITH IGNITION KEY IN CYLINDER (UNLOCK WARNING SW ON), WHEN THE DOOR IS OPENED AND LOCKED USING DOOR LOCK KNOB (DOOR LOCK MOTOR), THE DOOR IS LOCKED ONCE BUT EACH DOOR IS UNLOCKED SOON BY THE FUNCTION OF RELAY. AS A RESULT, THE CURRENT FLOWS FROM TERMINAL 8 OF THE RELAY → TERMINAL 3 → TERMINAL 2 OF THE DOOR LOCK MOTORS, (EX. C/P FRONT DOOR) OR TERMINAL 5 (C/P FRONT DOOR) OF THE DOOR LOCK MOTOR TERMINAL 2 OF THE BACK DOOR LOCK MOTOR → TERMINAL 4 OF THE DOOR LOCK MOTORS, (EX. C/P FRONT DOOR) OR TERMINAL 7 (C/P FRONT DOOR), OF THE DOOR LOCK MOTOR TERMINAL 1 OF THE BACK DOOR LOCK MOTOR → TERMINAL 4 OF THE RELAY → TERMINAL 16 → TO GROUND AND CAUSES ALL THE DOORS TO UNLOCK. * OPERATING DOOR LOCK CONTROL SW OR DOOR LOCK KEY SW WITH IGNITION KEY IN CYLINDER (UNLOCK WARNING SW ON), WHEN THE DOOR IS OPENED AND LOCKED USING DOOR LOCK CONTROL SW OR KEY SW, THE DOOR IS LOCKED ONCE BUT EACH DOOR IS UNLOCK BY THE FUNCTION OF SW CONTAINED IN MOTORS, WHICH THE SIGNAL IS INPUT TO TERMINAL 6 (DRIVER’S) OR 5 (PASSENGER’S) OF THE RELAY. ACCORDING TO THIS INPUT SIGNAL, THE CURRENT IN ECU FLOWS FROM TERMINAL 8 OF THE RELAY → TERMINAL 3 → TERMINAL 2 OF THE DOOR LOCK MOTORS, (EX. C/P FRONT DOOR) OR TERMINAL 5 (C/P FRONT DOOR) OF THE DOOR LOCK MOTOR TERMINAL 2 OF THE BACK DOOR LOCK MOTOR → TERMINAL 4 OF THE DOOR LOCK MOTORS, TERMINAL 1 OF THE BACK DOOR LOCK MOTOR → TERMINAL 4 OF THE RELAY → TERMINAL 16 → TO GROUND AND CAUSES ALL THE DOOR TO UNLOCK. * IN CASE OF KEY LESS LOCK WITH IGNITION KEY IN CYLINDER (UNLOCK WARNING SW ON), WHEN THE UNLOCK FUNCTION IS DISTURBED MORE THAN 0.2 SECONDS, FOR EXAMPLE PUSHING THE DOOR LOCK KNOB ETC., THE DOOR HOLDS ON LOCK CONDITION. CLOSING THE DOOR AFTER, DOOR COURTESY SW INPUTS THE SIGNAL INTO TERMINAL 2 OR 14 OF THE RELAY. BY THIS INPUT SIGNAL, THE ECU WORKS AND CURRENT FLOWS FROM TERMINAL 8 OF THE RELAY → TERMINAL 3 → TERMINAL 2 OF THE DOOR LOCK MOTORS, (EX. C/P FRONT DOOR) OR TERMINAL 5 (C/P FRONT DOOR) OF THE DOOR LOCK MOTOR TERMINAL 1 OF THE BACK DOOR LOCK MOTOR → TERMINAL 4 OF THE DOOR LOCK MOTORS, (EX. C/P FRONT DOOR) OR TERMINAL 7 (C/P FRONT DOOR), OF THE DOOR LOCK MOTOR TERMINAL 2 OF THE BACK DOOR LOCK MOTOR → TERMINAL 4 OF THE RELAY → TERMINAL 16 → TO GROUND AND CAUSES ALL THE DOORS TO UNLOCK. 163 DOOR LOCK SERVICE HINTS D8 DOOR LOCK CONTROL RELAY 16–GROUND : ALWAYS CONTINUITY 2–GROUND : CONTINUITY WITH DRIVER’S DOOR OPEN 8–GROUND : ALWAYS APPROX. 12 VOLTS 3–GROUND : APPROX. 12 VOLTS 0.2 SECONDS WITH FOLLOWING OPERATION *DOOR LOCK CONTROL SW UNLOCKED *DOOR LOCK CONTROL SW LOCKED WITH IGNITION KEY IN CYLINDER AND DRIVER’S DOOR OPEN (IGNITION KEY REMINDER FUNCTION) *DOOR LOCK KNOB LOCKED WITH IGNITION KEY IN CYLINDER AND DRIVER’S DOOR OPEN (IGNITION KEY REMINDER FUNCTION) *UNLOCKING THE DRIVER’S, PASSENGER’S DOOR CYLINDER WITH KEY 4–GROUND : APPROX. 12 VOLTS 0.2 SECONDS WITH FOLLOWING OPERATION *DOOR LOCK CONTROL SW LOCKED *LOCKING THE DRIVER’S, PASSENGER’S DOOR CYLINDER WITH KEY 10–GROUND : 0 VOLTS WITH DOOR LOCK CONTROL SW LOCKED 14–GROUND : CONTINUITY WITH PASSENGER’S DOOR OPEN 6–GROUND : CONTINUITY WITH DRIVER’S DOOR LOCK KNOB UNLOCKED 5–GROUND : CONTINUITY WITH PASSENGER’S DOOR LOCK KNOB UNLOCKED 11–GROUND : 0 VOLTS WITH DOOR LOCK CONTROL SW UNLOCKED, PASSENGER’S DOOR LOCK CYLINDER UNLOCKED WITH KEY 13–GROUND : 0 VOLTS WITH PASSENGER’S DOOR LOCK CYLINDER UNLOCKED WITH KEY 1–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ACC POSITION 9–GROUND : 0 VOLTS WITH DRIVER’S DOOR LOCK CYLINDER UNLOCKED WITH KEY 12–GROUND : 0 VOLTS WITH DRIVER’S, PASSENGER’S DOOR LOCK CYLINDER LOCKED WITH KEY D12, D13 DOOR COURTESY SW 1–GROUND : CLOSED WITH EACH DOOR OPEN D17, D18 DOOR KEY LOCK AND UNLOCK SW 3–2 : CLOSED WITH DOOR LOCK CYLINDER LOCKED WITH KEY 1–2 : CLOSED WITH DOOR LOCK CYLINDER UNLOCKED WITH KEY D20, D21 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW (C/P) 1–3 : CLOSED WITH UNLOCK POSITION D20, D21 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW (EX. C/P) 6–4 : CLOSED WITH UNLOCK POSITION I12 UNLOCK WARNING SW [IGNITION SW] 1–5 : CLOSED WITH IGNITION KEY IN CYLINDER : PARTS LOCATION CODE SEE PAGE B9 36 CODE D19 SEE PAGE 34 (S/D), 36 (W/G) J2 A 34 (S/D), 36 (W/G) J3 B 35 (C/P) D8 32 D12 34 (S/D), 35 (C/P), 36 (W/G) D13 34 (S/D), 35 (C/P), 36 (W/G) D21 34 (S/D), 35 (C/P), 36 (W/G) D17 34 (S/D), 35 (C/P), 36 (W/G) D22 34 (S/D), 35 (C/P), 36 (W/G) D18 34 (S/D), 35 (C/P), 36 (W/G) D23 34 (S/D), 35 (C/P), 36 (W/G) 34 (S/D), 36 (W/G) I12 33 D19 A D20 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1G 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 1H 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 1K 1L 1M : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) IG1 42 FLOOR NO. 1 WIRE AND INSTRUMENT PANEL WIRE IH2 42 FRONT DOOR LH WIRE AND INSTRUMENT PANEL WIRE II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE IT1 44 FRONT DOOR RH WIRE AND INSTRUMENT PANEL WIRE IU1 44 FLOOR NO. 2 WIRE AND INSTRUMENT PANEL WIRE BW1 BY1 46 (S/D) 50 (W/G) 46 (S/D) 50 (W/G) REAR DOOR LH WIRE AND FLOOR NO. NO 1 WIRE REAR DOOR RH WIRE AND FLOOR NO. NO 2 WIRE Bc1 50 (W/G) BACK DOOR NO. 1 WIRE AND FLOOR NO. 1 WIRE Bd3 50 (W/G) BACK DOOR NO. 1 WIRE AND BACK DOOR NO. 2 WIRE 164 CODE B P12 SEE PAGE 33 33 A 34 (S/D), 36 (W/G) B 34 (S/D), 35 (C/P), 36 (W/G) C 35 (C/P) : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION IF 42 LEFT KICK PANEL IG 42 INSTRUMENT PANEL BRACE LH IJ 42 RIGHT KICK PANEL : SPLICE POINTS CODE I3 I22 B1 B2 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS INSTRUMENT PANEL WIRE 46 (S/D) B2 B11 46 (S/D) 50 (W/G) CODE FRONT DOOR LH WIRE SEE PAGE 50 (W/G) 46 (S/D) 50 (W/G) WIRE HARNESS WITH SPLICE POINTS FRONT DOOR LH WIRE FRONT DOOR RH WIRE B18 48 (C/P) FRONT DOOR LH WIRE B27 48 (C/P) FRONT DOOR RH WIRE 165 BACK DOOR LOCK (W/G w/o POWER WINDOW) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 30A POWER W–L 2 1K II2 B3 BACK DOOR LOCK CONTROL SW L 10 LOCK 5 UNLOCK 6 1 3 16 L–B L–B IG1 4 3 L–B Bc1 L–B Bd3 L–R W–B 1 M B9 BACK DOOR LOCK MOTOR 2 6 L–R L–R IG1 2 1 L–R Bc1 L–R Bd3 IJ SERVICE HINTS B 3 BACK DOOR LOCK CONTROL SW 6–GROUND : ALWAYS APPROX. 12 VOLTS 5–GROUND : ALWAYS CONTINUITY : PARTS LOCATION CODE SEE PAGE B3 32 CODE SEE PAGE B9 CODE 36 (W/G) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE IK SEE PAGE 20 JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) IG1 38 FLOOR NO. 1 WIRE AND INSTRUMENT PANEL WIRE (LEFT KICK PANEL) IT2 40 FRONT DOOR RH WIRE AND INSTRUMENT PANEL WIRE (RIGHT KICK PANEL) Bc1 44 (W/G) BACK DOOR NO. 1 WIRE AND FLOOR NO. 1 WIRE (LEFT QUARTER TRIM INNER) Bd3 44 (W/G) BACK DOOR NO. 1 WIRE AND BACK DOOR NO. 2 WIRE (BACK DOOR LEFT) : GROUND POINTS CODE IJ SEE PAGE 38 GROUND POINTS LOCATION RIGHT KICK PANEL B3 1 B 9 GRAY X 3 X 5 6 1 166 2 SEE PAGE * 1 : TMC MADE * 2 : TMM MADE MOON ROOF SERVICE HINTS POWER MAIN RELAY 5–3 : CLOSED WITH IGNITION SW AT ON POSITION M 2 MOON ROOF CONTROL RELAY 11–GROUND : ALWAYS CONTINUITY 6–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 4–GROUND : APPROX. 12 VOLTS WITH IGNITION SW ON, AND MOON ROOF CONTROL SW AT CLOSE OR UP POSITION (EXCEPT APPROX. 100 MM (3.941 IN.) IN THE BEFORE CLOSED POSITION) 5–GROUND : APPROX. 12 VOLTS WITH IGNITION SW ON, AND MOON ROOF CONTROL SW AT OPEN OR DOWN POSITION 12–GROUND : ALWAYS APPROX. 12 VOLTS M 3 MOON ROOF CONTROL SW 5–4 : CLOSED WITH MOON ROOF CONTROL SW AT UP POSITION 6–4 : CLOSED WITH MOON ROOF CONTROL SW AT CLOSE POSITION 2–4 : CLOSED WITH MOON ROOF CONTROL SW AT DOWN POSITION 3–4 : CLOSED WITH MOON ROOF CONTROL SW AT OPEN POSITION 4–GROUND : ALWAYS CONTINUITY : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE CODE SEE PAGE D8 32 M2 34 (S/D), 35 (C/P), 36 (W/G) M4 34 (S/D), 35 (C/P), 36 (W/G) J3 33 M3 34 (S/D), 35 (C/P), 36 (W/G) M5 34 (S/D), 35 (C/P), 36 (W/G) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1C SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 20 ROOF WIRE AND J/B NO. 1 (INSTRUMENT PANEL) TMC MADE 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL) TMM MADE 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 2E 22 ENGINE ROOM MAIN WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 2G 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 1I 1K 1L 1M : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE IV1 44 ROOF WIRE AND COWL WIRE : GROUND POINTS CODE IG BK BP SEE PAGE 42 GROUND POINTS LOCATION INSTRUMENT PANEL BRACE LH 46 (S/D) 48 (C/P) 50 (W/G) ROOF LEFT BACK PANEL CENTER : SPLICE POINTS CODE B4 B5 B21 SEE PAGE 46 (S/D) WIRE HARNESS WITH SPLICE POINTS CODE B31 ROOF WIRE B32 SEE PAGE 50 (W/G) WIRE HARNESS WITH SPLICE POINTS ROOF WIRE 48 (C/P) 167 * 1 : S/D TMC MADE * 2 : S/D TMM MADE, W/G MOON ROOF FROM POWER SOURCE SYSTEM (SEE PAGE 64) 10A GAUGE 30A POWER 20A DOME 1 2 1K W–L R IV1 (W/G) IV2 (S/D, C/P) R 1 1 II2 M2 MOON ROOF CONTROL RELAY (*2) 1 1I (* 2) D8 DOOR LOCK CONTROL RELAY 1 L–R IG 8 +B R–L 15 RLY II2 R C 10 (* 1) J3 JUNCTION CONNECTOR 5 C 1 1C W–L II2 R–L 4 R 2 2G R–L 8 1K R–L 12 BUZZER 6 1L S 1 5 TIMER R Q POWER MAIN RELAY 5 TIMER 1I L 1 1M 3 (* 2) 2 TIMER 5 IV1 (W/G) 5 IV2 (S/D, C/P) L P G–Y 2 1 3 5 2 3 6 UP M 2 M5 MOON ROOF MOTOR 4 W–B W–B W–B W–B W–B IG 168 B 5 : S/D B32 : W/G B21 : C/P B 4 : S/D B31 : W/G B21 : C/P BK : S/D, C/P BP : W/G CLOSE 2 OPEN G 1 R–W R–L 1 11 DOWN 4 G–W 7 R–Y 5 W–B 9 M4 4 MOON ROOF LIMIT SW 3 R 8 NO. 2 W–B 6 (* 2) NO. 1 L (* 1) Q R S M3 MOON ROOF CONTROL SW SYSTEM OUTLINE CURRENT IS APPLIED AT ALL TIMES THROUGH POWER FUSE TO TERMINAL 5 OF POWER MAIN RELAY AND ALSO THROUGH DOME FUSE TO TERMINAL 12 OF MOON ROOF CONTROL RELAY. WITH THE IGNITION SW TURNED ON, THE CURRENT FLOWS FROM TERMINAL 1 OF POWER MAIN RELAY → TERMINAL 2 → TO GROUND THROUGH GAUGE FUSE. AS A RESULT, POWER MAIN RELAY IS ACTIVATED AND THE CURRENT TO TERMINAL 5 OF POWER MAIN RELAY FLOWS FROM TERMINAL 3 OF RELAY TO TERMINAL 6 OF MOON ROOF CONTROL RELAY. 1. SLIDE OPEN OPERATION WHEN THE IGNITION SW IS TURNED ON AND THE MOON ROOF CONTROL SW IS PUSHED TO THE OPEN POSITION, A SIGNAL IS INPUT FROM TERMINAL 3 OF MOON ROOF CONTROL SW TO TERMINAL 1 OF MOON ROOF CONTROL RELAY. MOON ROOF LIMIT SW NO. 2 ON AT THIS TIME. WHEN THIS OCCURS, THE RELAY IS ACTIVATED AND THE CURRENT TO TERMINAL 6 OF MOON ROOF CONTROL RELAY FLOWS FROM TERMINAL 5 → TERMINAL 1 OF MOON ROOF MOTOR → TERMINAL 3 → TERMINAL 4 OF MOON ROOF CONTROL RELAY → TERMINAL 11 → TO GROUND AND ROTATES THE MOTOR TO OPEN THE MOON ROOF WHILE THE SW IS BEING PUSHED TO OPEN POSITION. 2. SLIDE CLOSE OPERATION WITH THE IGNITION SW TURNED ON, THE MOON ROOF COMPLETELY OPEN AND MOON ROOF LIMIT SW NO. 1 AND NO. 2 BOTH ON, WHEN THE MOON ROOF CONTROL SW IS PUSHED TO THE CLOSE POSITION A SIGNAL IS INPUT FROM TERMINAL 6 OF MOON ROOF CONTROL SW TO TERMINAL 2 OF MOON ROOF CONTROL RELAY. WHEN THIS OCCURS, THE RELAY IS ACTIVATED AND THE CURRENT TO TERMINAL 6 OF MOON ROOF CONTROL RELAY FLOWS FROM TERMINAL 4 → TERMINAL 3 OF MOON ROOF MOTOR → TERMINAL 1 → TERMINAL 5 OF MOON ROOF CONTROL RELAY → TERMINAL 11 → TO GROUND AND ROTATES THE MOTOR TO CLOSE THE MOON ROOF WHILE THE SW IS BEING PUSHED TO CLOSE POSITION. MOON ROOF LIMIT SW NO. 1 TURNS OFF (LIMIT SW NO. 2 IS ON) AND A 100 MM BEFORE FULLY CLOSE POSITION, SIGNAL IS INPUT FROM TERMINAL 1 OF LIMIT SW NO. 1 TO TERMINAL 8 OF MOON ROOF CONTROL RELAY. THIS SIGNAL ACTIVATES THE RELAY AND STOPS CONTINUITY FROM TERMINAL 6 OF MOON ROOF CONTROL RELAY TO TERMINAL 11. AS A RESULT, THE MOON ROOF STOPS AT THIS POSITION. TO CLOSE THE MOON ROOF COMPLETELY, PUSHING THE MOON ROOF CONTROL SW AGAIN TO THE CLOSE SIDE CAUSES A SIGNAL TO BE INPUT AGAIN TO TERMINAL 2 OF MOON ROOF CONTROL RELAY. THIS ACTIVATES THE RELAY AND THE MOON ROOF WILL CLOSE AS LONG AS THE MOON ROOF CONTROL SW IS BEING PUSHED, ALLOWING THE MOON ROOF TO FULLY CLOSE. 3. TILT UP OPERATION WHEN THE MOON ROOF CONTROL SW IS PUSHED TO TILT UP POSITION, WITH THE IGNITION SW TURNED ON AND THE MOON ROOF COMPLETELY CLOSED (MOON ROOF LIMIT SW NO. 2 IS OFF), A SIGNAL IS INPUT FROM TERMINAL 5 OF MOON ROOF CONTROL SW TO TERMINAL 3 OF MOON ROOF CONTROL RELAY. AS A RESULT, THE RELAY IS ACTIVATED AND THE CURRENT TO TERMINAL 6 OF RELAY FLOWS FROM TERMINAL 4 OF RELAY → TERMINAL 3 OF MOON ROOF MOTOR → TERMINAL 1 → TERMINAL 5 OF RELAY → TERMINAL 11 TO GROUND AND ROTATES THE MOTOR SO THAT TILT UP OPERATION OCCURS AS LONG AS THE MOON ROOF CONTROL SW IS PUSHED ON THE TILT UP SIDE. 4. TILT DOWN OPERATION WHEN THE MOON ROOF CONTROL SW IS PUSHED TO TILT DOWN POSITION, WITH THE IGNITION SW TURNED ON AND THE MOON ROOF TILTED UP (NO. 1 AND NO. 2 MOON ROOF LIMIT SWITCHES ARE BOTH OFF), A SIGNAL IS INPUT FROM TERMINAL 2 OF MOON ROOF CONTROL SW TO TERMINAL 7 OF MOON ROOF CONTROL RELAY. AS A RESULT, THE RELAY IS ACTIVATED AND THE CURRENT TO TERMINAL 6 OF RELAY FLOWS FROM TERMINAL 5 OF RELAY → TERMINAL 1 OF MOON ROOF MOTOR → TERMINAL 3 → TERMINAL 4 OF RELAY → TERMINAL 11 → TO GROUND AND ROTATES THE MOTOR SO THAT TILT DOWN OPERATION OCCURS AS LONG AS THE MOON ROOF CONTROL SW IS PUSHED ON THE TILT DOWN SIDE. (DURING TILT DOWN, LIMIT SW NO. 1 IS CHANGED OFF TO ON.) 5. TILT UP REMINDER SYSTEM WHEN THE IGNITION SW IS TURNED FROM ON TO ACC OR OFF WITH THE MOON ROOF STILL TILTED UP THE CURRENT DOES NOT FLOW TO TERMINAL 6 OF MOON ROOF CONTROL RELAY. THIS IS RECEIVED BY THE RELAY AS A SIGNAL THAT THE IGNITION SW IS TURNED OFF. AT THIS TIME, MOON ROOF LIMIT SW NO.1 AND NO. 2 ARE OFF, SO SIGNALS ARE INPUT TO TERMINALS 8 AND 9 OF MOON ROOF CONTROL RELAY THAT THE MOON ROOF IS IN THE TILT OPERATION POSITION. WHEN THESE SIGNALS ARE INPUT TO THE MOON ROOF CONTROL RELAY, THE TIMER BUILT INTO THE RELAY OPERATES. THUS THE CURRENT TO TERMINAL 12 OF MOON ROOF CONTROL RELAY FLOWS THROUGH BUZZER OF MOON ROOF CONTROL RELAY AND TERMINAL 11 OF MOON ROOF CONTROL RELAY TO GROUND AND THE BUZZER SOUNDS ABOUT 8 TIMES TO NOTIFY THAT THE MOON ROOF IS STILL IN THE TILT UP CONDITION. 169 UNLOCK AND SEAT BELT WARNING FROM POWER SOURCE SYSTEM (SEE PAGE 64) 10A GAUGE R–L C C R–L 20A DOME 6 1B J1 JUNCTION CONNECTOR 2 2G 6 R C9 SEAT BELT WARNING LIGHT [COMB. METER] R–W 7 7 1C 1 1C INTEGRATION RELAY 9 7 1 BUZZER 6 8 2 1G 2 1H 5 1H 2 IO1 W–B 5 1 4 1G 1 D12 DOOR COURTESY SW FRONT LH R–Y (W/O POWER SEAT) R–Y I12 UNLOCK WARNING SW [IGNITION SW] 2 B7 BUCKLE SW 2 1 W–B W–B 1 1M B8 BUCKLE SW (W/G) 1 (W/ POWER SEAT) R–Y 5 R–L 10 R–G TIMER W–B 170 BL W–B (S/D, C/P) C C IG W–B C J5 JUNCTION CONNECTOR (S/D, C/P) W–B W–B (W/G) 5 IO1 SYSTEM OUTLINE CURRENT ALWAYS FLOWS TO TERMINAL 1 OF THE INTEGRATION RELAY THROUGH THE DOME FUSE. 1. SEAT BELT WARNING SYSTEM WHEN THE IGNITION SW IS TURNED ON, CURRENT FLOWS FROM THE GAUGE FUSE TO THE TERMINAL 7 OF THE INTEGRATION RELAY AT THE SAME TIME, CURRENT FLOWS TO TERMINAL 9 OF THE RELAY FROM THE GAUGE FUSE THROUGH THE SEAT BELT WARNING LIGHT. THIS CURRENT ACTIVATES THE SEAT BELT WARNING RELAY AND, CURRENT FLOWING THROUGH THE WARNING LIGHT FLOWS FROM TERMINAL 9 OF THE RELAY→ TERMINAL 10 → GROUND, CAUSING THE WARNING LIGHT TO LIGHT UP. AT THE SAME AS THE WARNING LIGHT LIGHTS UP. A BUCKLE SW OFF SIGNAL IS INPUT TO TERMINAL 8 OF THE RELAY, THE CURRENT FLOWING TO TERMINAL 1 OF THE RELAY FLOWS FROM TERMINAL 10 → GROUND AND THE SEAT BELT WARNING BUZZER SOUNDS FOR APPROX. 4–8 SECONDS. HOWEVER, IF SEAT BELT IS PUT ON DURING THIS PERIOD (WHILE THE BUZZER IS SOUNDING), SIGNAL INPUT TO TERMINAL 8 OF THE RELAY STOPS AND THE CURRENT FLOW FROM TERMINAL 1 OF THE RELAY → TERMINAL 10 → GROUND IS CUT, CAUSING THE BUZZER TO STOP. 2. UNLOCK WARNING SYSTEM WITH THE IGNITION KEY INSERTED IN THE KEY CYLINDER (UNLOCK WARNING SW ON), THE IGNITION SW STILL OFF AND DOOR OPEN (DOOR COURTESY SW ON), WHEN A SIGNAL IS INPUT TERMINAL 5 AND 6 OF THE RELAY, THE INTEGRATION RELAY OPERATES, CURRENT FLOWS FROM TERMINAL 1 OF THE RELAY → TERMINAL 10 → GROUND AND THE UNLOCK WARNING BUZZER SOUNDS. SERVICE HINTS B 7, B 8 BUCKLE SW 1–2 : CLOSED WITH DRIVR’S LAP BELT IN USE D12 DOOR COURTESY SW FRONT LH 1–GROUND : CLOSED WITH FRONT LH DOOR OPEN INTEGRATION RELAY 10–GROUND : ALWAYS CONTINUITY 6–GROUND : CONTINUITY WITH FRONT LH DOOR OPEN 5–GROUND : CONTINUITY WITH IGNITION KEY IN CYLINDER 8–GROUND : CONTINUITY UNLESS DRIVER’S LAP BELT IN USE 9–GROUND : 0 VOLTS WITH IGNITION SW ON AND BUCKLE SW OFF 1–GROUND : ALWAYS APPROX. 12 VOLTS 7–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION I12 UNLOCK WARNING SW [IGNITION SW] 1–5 : CLOSED WITH IGNITION KEY IN CYLINDER : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE B7 32 D12 34 (S/D), 35 (C/P), 36 (W/G) B8 32 I12 33 C9 32 J1 33 CODE J5 SEE PAGE 36 (W/G) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1B 1C 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 1G 1H 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 1M 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 2E 22 ENGINE ROOM MAIN WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE IO1 SEE PAGE 42 JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) FLOOR NO. 1 WIRE AND SEAT WIRE : GROUND POINTS CODE IG SEE PAGE 42 GROUND POINTS LOCATION INSTRUMENT PANEL BRACE LH 46 (S/D) BL 48 (C/P) UNDER THE LEFT QUARTER PILLAR 50 (W/G) 171 UNLOCK AND SEAT BELT WARNING 172 HORN FROM POWER SOURCE SYSTEM (SEE PAGE 64) 10A HORN 2 HORN RELAY 5 2G 3 2A G–W 3 G–B 1 G–W 10 C12 HORN SW [COMB. SW] 1 1 H5 HORN LH H6 HORN RH SERVICE HINTS HORN RELAY 2–3 : CLOSED WITH HORN SW ON : PARTS LOCATION CODE SEE PAGE C12 CODE 32 H5 SEE PAGE CODE 28 (1MZ–FE), 30 (5S–FE) H6 SEE PAGE 28 (1MZ–FE), 30 (5S–FE) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE 2A 2E SEE PAGE 22 JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ENGINE ROOM MAIN WIRE AND J/B NO NO. 2 (ENGINE COMPARTMENT LEFT) C12 BLACK H 5, H 6 BLACK 1 X X X X 10 173 SRS (SUPPLEMENTAL RESTRAINT SYSTEM) NOTICE: When inspecting or repairing the SRS (supplemental restraint system), perform the operation in accordance with the following precautionary instructions and the procedure and precautions in the Repair Manual for the applicable model year.
Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic 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.
Work must be started after 90 seconds from the time the Ignition SW is set to the “LOCK” position and the negative (–) terminal cable is disconnected from the battery. (The supplemental restraint system is equipped with a back–up power source so that if work is started within 90 seconds of disconnecting the negative (–) terminal cable of the battery, the SRS may be activated.) When the negative (–) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents momorized by each memory system. When work is finished, reset the clock and audio system as before and adjust the clock. This vehicle has tilt and telescopic steering, power seat and outside rear view mirror and power shoulder belt anchorage, which are all equipped with memory function, it is not possible to make a record of the customer, and ask the customer to adjust the features and reset the memory. To avoid erasing the memory of each memory system, never use a back–up power supply from outside the vehicle.
When removing the steering wheel pad or handling a new steering wheel pad, keep the pad upper surface facing upward. Also, lock the lock lever of the twin lock type connector at the rear of the pad and take care not to damage the connector. (Storing the pad with its metallic surface up may lead to a serious accident if the SRS inflates for some reason.)
Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise.
Never use SRS parts from another vehicle. When replacing SRS parts, replace them with new parts.
Never disassemble and repair the steering wheel pad, center SRS sensor assembly or front airbag sensors.
Before repairing the body, remove the airbag sensors if during repair shocks are likely to be applied to the sensors due to vibration of the body or direct tapping with tools or other parts.
Do not reuse a steering wheel pad or front airbag sensors. After evaluating whether the center airbag sensor assembly is damaged or not, decide whether or not to reuse it. (See the Repair Manual for the method for evaluating the center airbag sensor assembly.)
When troubleshooting the supplemental restraint system, use a high–impedance (Min. 10k
/V) tester.
The wire harness of the supplemental restraint system is integrated with the cowl wire harness assembly and engine wire harness assembly. The vehicle wiring harness exclusively for the airbag system is distinguished by corrugated yellow tubing, as are the connectors.
Do not measure the resistance of the airbag squib. (It is possible this will deploy the airbag and is very dangerous.)
If the wire harness used in the supplemental restraint system is damaged, replace the whole wire harness assembly. When the connector to the airbag front sensors can be repaired alone (when there is no damage to the wire harness), use the repair wire specially designed for the purpose. (Refer to the Repair Manual for the applicable Model year for details of the replacement method.)
INFORMATION LABELS (NOTICES) are attached to the periphery of the SRS components. Follow the instructions on the notices. 174 The supplemental restraint system has connectors which possess the functions described below: 1. SRS ACTIVATION PREVENTION MECHANISM Each connector contains a short spring plate. When the connector is disconnected, the short spring plate automatically connects the power source and grounding terminals of the squib to preclude a potential difference between the terminals. 2. ELECTRICAL CONNECTION CHECK MECHANISM This mechanism is designed to electrically check if connectors are connected correctly and completely. The electrical connection check mechanism is designed so that the connection detection pin connects with the diagnosis terminals when the connector housing lock is in the locked condition. 175 SRS (SUPPLEMENTAL RESTRAINT SYSTEM) 3. CONNECTOR TWIN–LOCK MECHANISM With this mechanism connectors (male and female connectors) are locked by two locking devices to increase connection reliability. If the primary lock is incomplete, ribs interfere and prevent the secondary lock. 176 FROM POWER SOURCE SYSTEM (SEE PAGE 64) 15A CIG/RADIO 9 1F 7. 5A SRS 5 1F 3 1F D3 DATA LINK CONNECTOR 2 (TDCL) AB D1 DATA LINK CONNECOR 1 (CHECK CONNECTOR) TC AB 4 TC 5 11 W–R C10 SRS WARNING LIGHT [COMB. METER] 2 IP1 8 IP3 LG–R Y–B 12 B–Y P–L B–O B–Y 12 LG–R 7. 5A IGN B–Y 16 3D 1 Y–B B–Y 17 3D B B B–Y B 13 14 IG2 C C J4 JUNCTION CONNECTOR (FOR SRS) 12 ACC C Y–B B 7 LA TC 3 4 B B W 2 1 1 2 B 2 CONNECTION DETECTION PIN A D– B F2 FRONT AIRBAG SENSOR RH E1 5 E2 6 1 1F 2 1F 1 1M 5 1M SPIRAL CABLE 2 F1 FRONT AIRBAG SENSOR LH D+ W–B A P+ W–B 2 CONNECTION DETECTION PIN P– W–B 1 W–B 9 W B +SR 8 W +SL 1 –SR 10 B –SL 11 W C3 CENTER AIRBAG SENSOR ASSEMBLY 1 A22 AIRBAG SQUIB (FRONT PASSENGER AIRBAG ASSEMBLY) A15 AIRBAG SQUIB (STEERING WHEEL PAD) IG IE 177 SRS (SUPPLEMENTAL RESTRAINT SYSTEM) SYSTEM OUTLINE THE SRS (SUPPLEMENTAL RESTRAINT SYSTEM) IS A DRIVER AND PASSENGER PROTECTION DEVICE WHICH HAS A SUPPLEMENTAL ROLE TO THE SEAT BELTS. WHEN THE IGNITION SW IS TURNED TO ACC OR ON, CURRENT FROM THE CIG/RADIO FUSE FLOWS TO TERMINAL 14 OF THE CENTER AIRBAG SENSOR ASSEMBLY. ONLY WHEN THE IGNITION SW IS ON DOES THE CURRENT FROM THE IGN FUSE FLOW TO TERMINAL 13. IF AN ACCIDENT OCCURS WHILE DRIVING, DECELERATION CAUSED BY A FRONTAL IMPACT IS DETECTED BY EACH SENSOR AND SWITCH, AND WHEN THE FRONTAL IMPACT EXCEEDS A SET LEVEL (WHEN THE SAFING SENSOR BUILT INTO THE CENTER AIRBAG SENSOR ASSEMBLY IS ON AND THE CENTER AIRBAG SENSOR IS ON, FRONT AIRBAG SENSORS ARE OFF), CURRENT FROM THE CIG/RADIO OR IGN FUSE FLOWS TO TERMINALS 2, 3 OF THE CENTER AIRBAG SENSOR ASSEMBLY → TERMINAL 1 OF THE AIRBAG SQUIB → SQUIB → TERMINAL 2 → TERMINALS 1, 4 OF CENTER AIRBAG SENSOR ASSEMBLY → TERMINAL 6, TERMINAL 5 OR BODY GROUND → GROUND. WHEN THE SAFING SENSOR BUILT INTO THE CENTER AIRBAG SENSOR ASSEMBLY IS ON AND THE FRONT AIRBAG SENSOR LH OR RH IS ON, CENTER AIRBAG SENSOR IS OFF CURRENT FROM THE CIG/RADIO OR IGN FUSE FLOWS TO TERMINALS 2, 3 OF THE CENTER AIRBAG SENSOR ASSEMBLY → TERMINAL 1 OF THE AIRBAG SQUIB → SQUIB → TERMINAL 2 → TERMINALS 1, 4 OF CENTER AIRBAG SENSOR ASSEMBLY → TERMINAL 8 OR 11 → TERMINAL 1 OF FRONT AIRBAG SENSOR → TERMINAL 2 → TERMINAL 9 OR 10 OF CENTER AIRBAG SENSOR ASSEMBLY → TERMINAL 6, TERMINAL 5 OR BODY GROUND → GROUND. WHEN THE SAFING SENSOR BUILT INTO THE CENTER AIRBAG SENSOR ASSEMBLY IS ON, AND THE FRONT AIRBAG SENSOR LH OR RH IS ON AND CENTER AIRBAG SENSOR IS ON ONE OF THE ABOVE–MENTIONED CIRCUITS IS ACTIVATED SO THAT CURRENT FLOWS TO THE AIRBAG SQUIB AND CAUSES IT TO OPERATE. THE BAG STORED INSIDE THE STEERING WHEEL PAD IS INSTANTANEOUSLY EXPANDED TO SOFTEN THE SHOCK TO THE DRIVER. : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE CODE SEE PAGE A15 32 D1 28 (1MZ–FE), 30 (5S–FE) F2 28 (1MZ–FE), 30 (5S–FE) C3 32 D3 32 J4 33 C10 32 F1 28 (1MZ–FE), 30 (5S–FE) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1F 1M 3D SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 24 COWL WIRE AND J/B NO. 3 (BEHIND COMBINATION METER) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE IP1 IP3 SEE PAGE 44 JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ENGINE WIRE AND COWL WIRE : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION IE 42 LEFT KICK PANEL IG 42 INSTRUMENT PANEL BRACE LH 178 179 POWER SEAT FROM POWER SOURCE SYSTEM (SEE PAGE 64) 30A POWER R–W 20 1H IO1 R–W 4 P4 POWER SEAT CONTROL SW 10 FR RR UP DOWN UP DOWN FR RR 5 8 2 6 12 11 4 7 L–B L–Y R L–R W–B 9 W–B C J5 JUNCTION CONNECTOR W–B (W/G) C BL 180 M 1 P8 POWER SEAT MOTOR (FOR SLIDE CONTROL) (W/G) W–B (S/D, C/P) 2 1 M 2 P5 POWER SEAT MOTOR (FOR REAR VERTICAL CONTROL) 1 M 2 P6 POWER SEAT MOTOR (FOR FRONT VERTICAL CONTROL) 2 R–B M (EX. C/P) R–G (EX. C/P) L–W L 5 IO1 1 P7 POWER SEAT MOTOR (FOR RECLINING MOTOR CONTROL) SERVICE HINTS P 4 POWER SEAT CONTROL SW 10–GROUND : ALWAYS APPROX. 12 VOLTS 9–GROUND : ALWAYS CONTINUITY : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE CODE SEE PAGE J5 36 (W/G) P5 33 P7 33 P4 33 P6 33 P8 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1H SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE IO1 SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) 42 FLOOR NO. 1 WIRE AND SEAT WIRE : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION 46 (S/D) BL 48 (C/P) UNDER THE LEFT QUARTER PILLAR 50 (W/G) J5 P4 C C C C C C ORANGE P6 1 1 2 2 ORANGE P8 2 X 5 4 X 8 7 C C (HINT : SEE PAGE 7) WHITE P5 C C 6 P7 GRAY 12 11 10 9 GREEN 1 1 2 2 181 SHIFT LOCK FROM POWER SOURCE SYSTEM (SEE PAGE 64) 15A CIG/RADIO 9 1L 15A ECU–IG 15A STOP 2 1L 3 1M L–R B–R G–R G–W 2 A 1 A N2 A ,N3 B NOISE FILTER (FOR STOP LIGHT) 11 II2 4 1L 2 B 1 B G–R II2 L–R 9 G–W 6 1M 1 B B–R J3 JUNCTION CONNECTOR G–W B S10 STOP LIGHT SW 2 II2 G–W L–R 20 1 3 S5 SHIFT LOCK ECU 6 SHIFT LOCK CONTROL SW P1 G–R P G P2 G–W SL– L–R SHIFT LOCK SOLENOID SL+ 5 L–B 4 W–B II1 L–B 3 B J2 JUNCTION CONNECTOR 2 K3 KEY INTERLOCK SOLENOID B IE 182 W–B W–B 1 IF L–R SYSTEM OUTLINE WHEN THE IGNITION SW IS TURNED TO ACC POSITION THE CURRENT FROM THE CIG/RADIO FUSE FLOWS TO TERMINAL 1 OF THE SHIFT LOCK ECU. WHEN THE IGNITION SW IS TURNED TO ON POSITION THE CURRENT FROM THE ECU–IG FUSE FLOWS TO TERMINAL 3 OF THE ECU. 1. SHIFT LOCK MECHANISM WITH THE IGNITION SW ON, WHEN A SIGNAL THAT THE BRAKE PEDAL IS DEPRESSED (STOP LIGHT SW ON) AND A SIGNAL THAT THE SHIFT LEVER IS PUT IN “P” POSITION (CONTINUITY BETWEEN P1 AND P OF THE SHIFT LOCK CONTROL SW) IS INPUT TO THE ECU, THE ECU OPERATES AND CURRENT FLOWS FROM TERMINAL 3 OF THE ECU → TERMINAL SL+ OF THE SHIFT LOCK SOLENOID → SOLENOID → TERMINAL SL– → TERMINAL 5 OF THE ECU → GROUND. THIS CAUSES THE SHIFT LOCK SOLENOID TO TURN ON (PLATE STOPPER DISENGAGES) AND THE SHIFT LEVER CAN SHIFT INTO OTHER POSITION THAN THE “P” POSITION. 2. KEY INTERLOCK MECHANISM WITH THE IGNITION SW IN ON OR ACC POSITION, WHEN THE SHIFT LEVER IS PUT IN “P” POSITION (NO CONTINUITY BETWEEN P2 AND P OF SHIFT LOCK CONTROL SW), THE CURRENT FLOWING FROM TERMINAL 4 OF THE ECU → KEYINTERLOCK SOLENOID IS CUT OFF. THIS CAUSES THE KEYINTERLOCK SOLENOID TO TURN OFF (LOCK LEVER DISENGAGES FROM LOCK POSITION) AND THE IGNITION KEY CAN BE TURNED FROM ACC TO LOCK POSITION. SERVICE HINTS S 5 SHIFT LOCK ECU 1–GROUND : 3–GROUND : 5–GROUND : 6–GROUND : 4–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ACC OR ON POSITION APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION ALWAYS CONTINUITY APPROX. 12 VOLTS WITH BRAKE PEDAL DEPRESSED 0 VOLTS WITH IGNITION SW AT ACC POSITION AND SHIFT LEVER POSITION IN P POSITION 6–12 VOLTS WITH SHIFT LEVER POSITION IN EXCEPT P POSITION : PARTS LOCATION CODE SEE PAGE CODE J2 33 N2 J3 33 N3 K3 33 SEE PAGE A 33 B 33 S5 CODE S10 SEE PAGE 33 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1L 1M SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) II1 42 COWL WIRE AND INSTRUMENT PANEL WIRE II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE : GROUND POINTS CODE IE IF SEE PAGE 42 GROUND POINTS LOCATION LEFT KICK PANEL J2 J3 K3 N2 A B B B B B B B B 1 B B B B 2 2 1 B B (HINT : SEE PAGE 7) (HINT : SEE PAGE 7) S5 N3 B 1 2 S10 1 X 3 4 5 6 1 BLUE 2 183 FRONT WIPER AND WASHER FROM POWER SOURCE SYSTEM (SEE PAGE 64) C13 BLACK X 4 X X X F9 X 7 13 X W 1 BLACK 8 X 18 X 16 BLACK 1 2 3 X 5 6 1 20A WIPER 2 L 2 1M L L I5 17 IR1 L WASHER HIGH LOW INT MIST OFF C13 FRONT WIPER AND WASHER SW (W/ WIPER RELAY) [COMB. SW] 8 11 L–W L–W 1 2 IR1 L M E1 W1 WASHER MOTOR L 16 4 L–Y 7 L–B 13 L–O IR1 14 2 3 6 5 M 1 W–B F9 FRONT WIPER MOTOR IE 184 IR1 L–Y 15 L IR1 L–B 16 L–O W–B 18 EA SYSTEM OUTLINE WITH THE IGNITION SW TURNED ON, THE CURRENT FLOWS TO TERMINAL 18 OF THE WIPER AND WASHER SW, TERMINAL 2 OF THE WASHER MOTOR AND TERMINAL 4 OF THE WIPER MOTOR THROUGH THE WIPER FUSE. 1. LOW SPEED POSITION WITH WIPER SW TURNED TO LOW POSITION, THE CURRENT FLOWS FROM TERMINAL 18 OF THE WIPER AND WASHER SW → TERMINAL 7 → TERMINAL 3 OF THE WIPER MOTOR → WIPER MOTOR → TERMINAL 1 → TO GROUND AND CAUSES TO THE WIPER MOTOR TO RUN AT LOW SPEED. 2. HIGH SPEED POSITION WITH WIPER SW TURNED TO HIGH POSITION, THE CURRENT FLOWS FROM TERMINAL 18 OF THE WIPER AND WASHER SW → TERMINAL 13 → TERMINAL 2 OF THE WIPER MOTOR → WIPER MOTOR → TERMINAL 1 → TO GROUND AND CAUSES TO THE WIPER MOTOR TO RUN AT HIGH SPEED. 3. INT POSITION WITH WIPER SW TURNED TO INT POSITION, THE RELAY OPERATES AND THE CURRENT WHICH IS CONNECTED BY RELAY FUNCTION FLOWS FROM TERMINAL 18 OF THE WIPER AND WASHER SW → TERMINAL 16 → TO GROUND. THIS FLOW OF CURRENT OPERATES THE INTERMITTENT CIRCUIT AND THE CURRENT FLOWS FROM TERMINAL 18 OF THE WIPER AND WASHER SW → TERMINAL 7 → TERMINAL 3 OF THE WIPER MOTOR → TERMINAL 1 → TO GROUND AND THE WIPER FUNCTIONS. THE INTERMITTENT OPERATION IS CONTROLLED BY A CONDENSER’S CHARGED AND DISCHARGED FUNCTION INSTALLED IN RELAY AND THE INTERMITTENT TIME IS CONTROLLED BY A TIME CONTROL SW TO CHANGE THE CHARGING TIME OF THE CONDENSER. 4. WASHER CONTINUOUS OPERATION WITH WASHER SW TURNED TO ON, THE CURRENT FLOWS FROM TERMINAL 2 OF THE WASHER MOTOR → TERMINAL 1 → TERMINAL 8 OF THE WIPER AND WASHER SW → TERMINAL 16 → TO GROUND AND CAUSES TO THE WASHER MOTOR TO RUN AND WINDOW WASHER TO JET. THIS CAUSES THE CURRENT TO FLOW TO WASHER CONTINUOUS OPERATION CIRCUIT IN TERMINAL 18 OF THE WIPER AND WASHER SW → TERMINAL 7 → TERMINAL 3 OF THE WIPER MOTOR → TERMINAL 1 → TO GROUND AND THE WIPER FUNCTION. SERVICE HINTS C13 FRONT WIPER AND WASHER SW (W/ WIPER RELAY) [COMB. SW] 16–GROUND : ALWAYS CONTINUITY 18–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 7–GROUND : APPROX. 12 VOLTS WITH WIPER AND WASHER SW AT LOW OR MIST POSITION APPROX. 12 VOLTS 2 TO 12 SECONDS INTERMITTENTLY WITH WIPER SW AT INT POSITION 4–GROUND : APPROX. 12 VOLTS WITH IGNITION SW ON UNLESS WIPER MOTOR AT STOP POSITION 13–GROUND : APPROX. 12 VOLTS WITH WIPER AND WASHER SW AT HIGH POSITION F 9 FRONT WIPER MOTOR 5–6 : CLOSED UNLESS WIPER MOTOR AT STOP POSITION : PARTS LOCATION CODE SEE PAGE C13 CODE 32 F9 SEE PAGE CODE 28 (1MZ–FE), 30 (5S–FE) W1 SEE PAGE 28 (1MZ–FE), 30 (5S–FE) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1H 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 1M 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE IR1 SEE PAGE 44 JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ENGINE ROOM MAIN WIRE AND COWL WIRE : GROUND POINTS CODE EA IE SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 42 GROUND POINTS LOCATION FRONT RIGHT FENDER LEFT KICK PANEL : SPLICE POINTS CODE E1 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) WIRE HARNESS WITH SPLICE POINTS ENGINE ROOM MAIN WIRE CODE I5 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS COWL WIRE 185 REAR WIPER AND WASHER FROM POWER SOURCE SYSTEM (SEE PAGE 64) C13 REAR WIPER AND WASHER SW [COMB. SW] 20A WIPER WASHER OFF 15 1H 2 1M INT ON L 18 L–O W–B P–B I7 L–O IR1 P–G L IR1 W1 WASHER MOTOR 2 3 L–O M 16 (CANADA) 17 10 P–G 1 L–O 2 (USA) L WASHER L 8 IJ1 P–G IJ1 8 6 3 4 L B36 14 P–B R19 REAR WIPER RELAY IJ1 L–O 4 6 Bd1 8 Bd1 7 Bd1 W–B 7 Bc3 L–W 6 Bc3 L–Y L–W 7 L 8 Bc3 1 L–Y 2 J5 JUNCTION CONNECTOR L–W L–Y L C 3 4 M W–B 2 R18 REAR WIPER MOTOR W–B 1 W–B L C BR 186 BL IE SYSTEM OUTLINE WHEN THE IGNITION SW IS TURNED ON, CURRENT FLOWS TO TERMINAL 2 OF WASHER MOTOR, TERMINAL 4 OF REAR WIPER RELAY AND TERMINAL 1 OF REAR WIPER MOTOR THROUGH THE WIPER FUSE. 1. REAR WIPER NORMAL OPERATION WITH THE IGNITION SW TURNED ON AND REAR WIPER AND WASHER SW TURNED ON, THE CURRENT FLOWING TO TERMINAL 4 OF REAR WIPER RELAY FLOWS TO TERMINAL 6 OF RELAY → TERMINAL 1 OF REAR WIPER AND WASHER SW → TERMINAL 16 → TO GROUND. THUS, THE RELAY COIL IS ACTIVATED AND THE CURRENT TO TERMINAL 4 OF RELAY FLOWS TO TERMINAL 1 → TERMINAL 4 OF REAR WIPER MOTOR → MOTOR → TERMINAL 2 → TO GROUND AND CAUSES THE MOTOR TO OPERATE THE WIPER. 2. REAR WIPER INTERMITTENT OPERATION WITH THE IGNITION SW TURNED ON AND REAR WIPER AND WASHER SW TURNED TO INT POSITION, THE CURRENT FLOWING TO TERMINAL 4 OF REAR WIPER RELAY FLOWS TO TERMINAL 3 OF RELAY → TERMINAL 10 OF WIPER SW → TERMINAL 16 → TO GROUND. AS A RESULT, THE RELAY OPERATES AND CURRENT FLOWS FROM TERMINAL 4 OF RELAY → TERMINAL 1 → TERMINAL 4 OF REAR WIPER MOTOR → MOTOR → TERMINAL 2 → TO GROUND, CAUSING THE MOTOR TO ROTATE TO OPERATE THE WIPER. AT THIS TIME THE CONTACT IN THE WIPER MOTOR CLOSED AND THE CURRENT FLOWS FROM TERMINAL 1 OF REAR WIPER MOTOR → TERMINAL 3 → TERMINAL 2 OF REAR WIPER RELAY → TERMINAL 1 → TERMINAL 4 OF REAR WIPER MOTOR → TERMINAL 2 → TO GROUND. THUS, THE INTERMITTENT–STOP CIRCUIT OPERATES, THE CONDENOR IN THE CIRCUIT CHARGES AND THE WIPER CONTINUES TO OPERATE UNTIL REACHING THE STOP POSITION. AFTER THE WIPER STOPS, CURRENT DOES NOT FLOW TO THE INTERMITTENT–STOP CIRCUIT FROM TERMINAL 2 OF RELAY, BUT THE CONDENSER DISCHARGES CURRENT INTO THE INTERMITTENT CIRCUIT AND THE CIRCUIT OPERATES UNTIL THE CONDENSER DISCHARGE ENDS. AS A RESULT, THIS DISCHARGE INTERVAL BECOMES THE INTERMITTENT TIME. WHEN THE CURRENT IS DISCHARGED COMPLETELY, THE CURRENT FLOWING TO TERMINAL 4 OF RELAY FLOWS TO TERMINAL 3 → TERMINAL 10 OF REAR WIPER AND WASHER SW → TERMINAL 16 → TO GROUND. THEN, THE CURRENT IN TERMINAL 4 OF RELAY FLOWS FROM TERMINAL 1 → TERMINAL 4 OF MOTOR → MOTOR → TERMINAL 2 → TO GROUND AND ROTATES THE MOTOR. THROUGH REPEITION OF THIS PROCESS, INTERMITTENT OPERATION OF THE REAR WIPER OCCURS. 3. WASHER OPERATION WITH THE IGNITION SW ON AND THE REAR WIPER AND WASHER SW IS TURNED STRONGLY (WASHER SW ON), CURRENT FLOWS FROM TERMINAL 2 OF WASHER MOTOR → TERMINAL 3 → TERMINAL 2 OF REAR WIPER AND WASHER SW → TERMINAL 16 → TO GROUND SO THAT THE WASHER MOTOR ROTATES AND WINDOW WASHER EJECTS THE SPRAY, ONLY THE WHILE THE REAR WASHER SW IS TURNED, WHEN THE REAR WIPER SW IS OFF, AND THE REAR WIPER AND WASHER SW IS THEN TURNED IN THE OFF DIRECTION, WASHER LIQUID WILL ALSO SPLAY. SERVICE HINTS R19 REAR WIPER RELAY 4–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 7–GROUND : ALWAYS CONTINUITY 1–4 : POINTS CHANGES EVERY APPROX. 9–15 SECONDS INTERMITTENTLY WITH IGNITION SW ON AND WIPER SW AT INT POSITION W 1 WASHER MOTOR 2–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 3–GROUND : CONTINUITY WITH WASHER SW TURNED ON 187 REAR WIPER AND WASHER : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE C13 32 R18 36 (W/G) J5 36 (W/G) R19 36 (W/G) CODE W1 SEE PAGE 29 (1MZ–FE), 30 (5S–FE) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1H 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 1M 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) IJ1 42 FLOOR NO. 1 WIRE AND COWL WIRE IR1 44 ENGINE ROOM MAIN WIRE AND COWL WIRE Bc1 50 (W/G) BACK DOOR NO. 1 WIRE AND FLOOR NO. 1 WIRE Bd1 50 (W/G) BACK DOOR NO. 1 WIRE AND BACK DOOR NO. 2 WIRE : GROUND POINTS CODE IE SEE PAGE 42 GROUND POINTS LOCATION LEFT KICK PANEL 46 (S/D) BL 48 (C/P) UNDER THE LEFT QUARTER PILLAR 50 (W/G) BR 50 (W/G) BACK DOOR CENTER : SPLICE POINTS CODE I7 188 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS COWL WIRE CODE B36 SEE PAGE 50 (W/G) WIRE HARNESS WITH SPLICE POINTS FLOOR NO. 1 WIRE CIGARETTE LIGHTER AND CLOCK FROM POWER SOURCE SYSTEM (SEE PAGE 64) SERVICE HINTS 15A CIG/RADIO C 4 CIGARETTE LIGHTER 2–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ACC OR ON POSITION 1–GROUND : ALWAYS CONTINUITY C 6 CLOCK 3–GROUND : ALWAYS APPROX. 12 VOLTS (POWER FOR CLOCK) 4–GROUND : APPROX .12 VOLTS WITH IGNITION SW AT ACC OR ON POSITION (POWER FOR INDICATION) 2–GROUND : APPROX .12 VOLTS WITH LIGHT CONTROL SW AT TAIL OR HEAD POSITION APPROX. 12 VOLTS WITH ENGINE RUNNING AND PARKING BRAKE RELEASED (CANADA) 1–GROUND : ALWAYS CONTINUITY 20A DOME 2 2G L–R 7 1D L–R L–R R I7 C4 2 4 C6 C4 CIGARETTE LIGHTER 1 C6 CLOCK 2 1 1 2 3 4 2 G 1 W–B BLACK 3 W–B J2 DARK GRAY F J2 JUNCTION CONNECTOR 21 3C W–B F F F F 9 3D (HINT : SEE PAGE 7) G 8 1C 5 1M W–B FROM TAIL FUSE IE : PARTS LOCATION CODE SEE PAGE C4 32 CODE C6 SEE PAGE CODE 32 J2 SEE PAGE 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1B 1C 1D 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 22 ENGINE ROOM MAIN WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 1M 2E : GROUND POINTS CODE IE SEE PAGE 42 GROUND POINTS LOCATION LEFT KICK PANEL : SPLICE POINTS CODE I7 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS COWL WIRE 189 REAR WINDOW DEFOGGER FROM POWER SOURCE SYSTEM (SEE PAGE 64) 10A GAUGE 40A DEFOG 2 R–L 6 1D 3 TIMER 6 Y–L 8 1D 2 5 DEFOGGER RELAY R5 REAR WINDOW DEFOGGER SW 2 1 1 3 2 NOISE FILTER 1 1M B (W/G) W–B 10 1C 10 1H W–B I7 B (S/D, C/P) W–B B 1 Bc1 2 Bd3 F B J2 JUNCTION CONNECTOR W–B F D B 1 B (W/G) 1 D (S/D, C/P) 190 BS B B IE (W/G) W–B 5 1M 1 A (W/G) 1 C (S/D, C/P) (S/D, C/P) 8 1C R16 A C , R17 B REAR WINDOW DEFOGGER W–B 1 Be1 BN IG SERVICE HINTS DEFOGGER RELAY 5–3 : CLOSED WITH IGNITION SW ON, DEFOGGER SW ON REAR WINDOW DEFOGGER SW R5 3–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 2–GROUND : ALWAYS CONTINUITY 3–6 : CONTINUITY WITH DEFOGGER SW ON : PARTS LOCATION CODE SEE PAGE J2 33 R5 33 CODE R16 SEE PAGE CODE A 34 (S/D), 35 (C/P), 36 (W/G) C 34 (S/D), 35 (C/P), 36 (W/G) R17 SEE PAGE B 34 (S/D), 35 (C/P), 36 (W/G) D 34 (S/D), 35 (C/P), 36 (W/G) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1C SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 1H 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 1M 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 1D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) Bc1 50 (W/G) BACK DOOR NO. 1 WIRE AND FLOOR NO. 1 WIRE Bd3 50 (W/G) BACK DOOR NO. 1 WIRE AND BACK DOOR NO. 2 WIRE Be1 50 (W/G) REAR WINDOW NO. 1 WIRE AND BACK DOOR NO. 2 WIRE : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION IE 42 LEFT KICK PANEL IG 42 INSTRUMENT PANEL BRACE LH BN BS 46 (S/D) UNDER THE RIGHT QUARTER PILLAR 48 (C/P) 50 (W/G) BACK DOOR RIGHT : SPLICE POINTS CODE I7 SEE PAGE WIRE HARNESS WITH SPLICE POINTS 44 CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS COWL WIRE J2 DARK GRAY R5 BLUE R16 A , R 17 B R16 C BLACK , R17 D BLACK 1 F F X 2 3 6 1 F (HINT : SEE PAGE 7) 191 CRUISE CONTROL I12 IGNITION SW AM1 FROM POWER SOURCE SYSTEM (SEE PAGE 64) 10A GAUGE IG1 ST1 ACC 15A ECU–IG J1 JUNCTION CONNECTOR C C 7 7 1A 6 1D 6 1B R–L R–L C8 B–R 16 3C A R–L B–W 6 1G B , C9 COMBINATON METER 6 A 6 (A/T) O (* 2) (* 1) G–L 19 3B 20 5 SPD CMS A/D PI TC R–W I13 17 15 3B 12 3B 16 3D 8 3D RESUME/ ACCEL 20 8 C13 CRUISE CONTROL SW [COMB. SW] 11 1C 1 1M TC W–B IG 192 1 P3 PARKING BRAKE SW W–B II1 IP3 11 18 3C R–W 4 5 3B R–W 14 3B CANCEL D1 DATA LINK CONNECTOR 1 (CHECK CONNECTOR) LG–R W–B 2 R–W W–B LG–R SET/ COAST 8 3C 1 P2 PARKING BRAKE SW C15 CRUISE CONTROL CLUTCH SW (M/T) W–B LG–R B 1 (M/T) 17 3B 3 W MAIN 18 3B (M/T) TO STARTER RELAY 7 3B PKB 8 (1MZ–FE) 15 CCS 18 (5S–FE) 4 W–L GND 13 B 2 W–B N&C (* 1) (* 2) O 10 B B 9 3B G–L 2 V5 VEHICLE SPEED SENSOR (SPEED SENSOR) G–Y 3 C16 CRUISE CONTROL ECU 14 B 10 3B IP3 O 1 11 (* 2) D3 DATA LINK CONNECTOR 2 (TDCL) 1 R–L IP3 (* 1) N 8 3B V–Y 14 B–R 2 9 B R–L I18 D5 DIODE (FOR CRUISE CONTROL) 5 P 22 3D P (A/T) B–W (A/T) 1 EF1 TO BACK–UP LIGHT SW (M/T) TO PARK/NEUTRAL POSITION SW (NEUTRAL START SW)(A/T) TO GENERATOR (ALTERNATOR) G 16 3B R–L 14 1A B–W P1 PARK/NEUTRAL POSITION SW (NEUTRAL START SW) B–W 5 1E IP3 4 B LG 2 5 B V–Y 12 B G–B CRUISE SPEED * 1 : TMC MADE * 2 : TMM MADE FROM POWER SOURCE SYSTEM (SEE PAGE 64) 15A STOP 3 1M G–R C (A/T) B ,E8 32 A 12 C A ,N3 OD1 3 S10 STOP LIGHT SW 2 A 7 B (1MZ–FE) (5S–FE) 17 A 2 1 B 2 B 1 G–W G–W S2 N2 IDL B 1 A ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) NOISE FILTER (FOR STOP LIGHT) A , E10 C (M/T) G–R E7 E14 G–B G–R 4 R–Y 12 1A (A/T) P–L G–W G–R G–R Y–B 15 1A (A/T) L 6 1M (5S–FE) L–W (1MZ–FE) I23 19 3C IP1 23 22 13 3B G–W V–R 5 (A/T) IP3 L 17 IDL ECT 9 1 OD STP+ 15 16 BATT STP– L 12 R–B R–G 3 IR1 2 IR1 1 IR1 R–Y IR1 R–G 7 R–B IR1 R–Y L 8 C16 CRUISE CONTROL ECU L–B IR1 G–B MO 11 L MC 24 L–B VR1 25 L–R 9 VR2 26 L–R VR3 10 3 2 1 7 6 5 M C2 CRUISE CONTROL ACTUATOR 4 W–B 8 6 2E 2B W–B EB 193 CRUISE CONTROL : PARTS LOCATION CODE SEE PAGE C2 CODE 28 (1MZ–FE), 30 (5S–FE) SEE PAGE D5 CODE 32 N3 SEE PAGE B 33 C8 B 32 E7 A 32 P1 29 (1MZ–FE), 31 (5S–FE) C9 A 32 E8 C 32 P2 33 C13 32 E10 B 32 P3 33 C15 32 E14 C 32 S10 33 C16 32 I12 33 V5 29 (1MZ–FE), 31 (5S–FE) D1 28 (1MZ–FE), 30 (5S–FE) J1 33 D3 32 N2 A 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1A 1B 1C 1D 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 22 ENGINE ROOM MAIN WIRE AND J/B NO NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO. 3 (BEHIND COMBINATION METER) 1E 1G 1M 2B 2E 3B 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE EF1 II1 IP1 IP3 IR1 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ENGINE WIRE AND COWL WIRE 42 COWL WIRE AND INSTRUMENT PANEL WIRE 44 ENGINE WIRE AND COWL WIRE 44 ENGINE ROOM MAIN WIRE AND COWL WIRE : GROUND POINTS CODE EB IG SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 42 GROUND POINTS LOCATION FRONT LEFT FENDER INSTRUMENT PANEL BRACE LH : SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS I13 44 COWL WIRE I18 44 ENGINE WIRE 194 CODE I23 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS COWL WIRE 195 CRUISE CONTROL SYSTEM OUTLINE CURRENT IS APPLIED AT ALL TIMES THROUGH STOP FUSE TO TERMINAL 1 OF THE CRUISE CONTROL ECU AND TERMINAL 2 OF STOP LIGHT SW, AND ALSO THROUGH THE STOP FUSE TO TERMINAL 15 OF CRUISE CONTROL ECU. WITH THE IGNITION SW TURNED TO ON, THE CURRENT FLOWS THROUGH GAUGE FUSE TO TERMINAL (A) 6 OF COMBINATION METER AND THE CURRENT THROUGH ECU–IG FUSE FLOWS TO TERMINAL 14 OF CRUISE CONTROL ECU. WHEN THE IGNITION SW IS ON AND THE CRUISE CONTROL MAIN SW IS TURNED ON, A SIGNAL IS INPUT FROM TERMINAL 15 OF CRUISE CONTROL MAIN SW TO TERMINAL 4 OF CRUISE CONTROL ECU. AS A RESULT, THE CRUISE CONTROL ECU FUNCTIONS AND THE CURRENT TO TERMINAL 14 OF CRUISE CONTROL ECU TO TERMINAL 13 OF CRUISE CONTROL ECU → GROUND, AND THE CRUISE CONTROL SYSTEM IS IN A CONDITION READY FOR OPERATION. AT THE SAME TIME, THE CURRENT THROUGH THE GAUGE FUSE FLOWS FROM TERMINAL (A) 6 OF CRUISE CONTROL INDICATOR LIGHT → TERMINAL (B) 9 → TERMINAL 5 OF CRUISE CONTROL ECU → TERMINAL 13 → TO GROUND, CAUSING THE CRUISE CONTROL INDICATOR LIGHT TO LIGHT UP, INDICATING THAT THE CRUISE CONTROL IS READY FOR OPERATION. 1. SET OPERATION WHEN THE CRUISE CONTROL MAIN SW IS TURNED ON AND THE SET SW IS TURNED ON WITH THE VEHICLE SPEED WITHIN THE SET LIMIT (APPROX. 40 KM/H, 25 MPH TO 200 KM/H, 124 MPH), A SIGNAL IS INPUT TO TERMINAL 18 OF THE CRUISE CONTROL ECU AND THE VEHICLE SPEED AT THE TIME THE SET SW IS RELEASED IS MEMORIZED IN THE ECU AS THE SET SPEED. 2. SET SPEED CONTROL DURING CRUISE CONTROL DRIVING, THE ECU COMPARES THE SET SPEED MEMORIZED IN THE ECU WITH THE ACTUAL VEHICLE SPEED INPUT INTO TERMINAL 20 OF THE CRUISE CONTROL ECU FROM THE VEHICLE SPEED SENSOR (SPEED SENSOR), AND CONTROLS THE CRUISE CONTROL ACTUATOR TO MAINTAIN THE SET SPEED. WHEN THE ACTUAL SPEED IS LOWER THAN THE SET SPEED, THE ECU CAUSES THE CURRENT TO THE CRUISE CONTROL ACTUATOR TO FLOW FROM TERMINAL 12 → TERMINAL 6 OF CRUISE CONTROL ACTUATOR → TERMINAL 7 → TERMINAL 11 OF CRUISE CONTROL ECU. AS A RESULT, THE MOTOR IN THE CRUISE CONTROL ACTUATOR IS ROTATED TO OPEN THE THROTTLE VALVE AND THE THROTTLE CABLE IS PULLED TO INCREASE THE VEHICLE SPEED. WHEN THE ACTUAL DRIVING SPEED IS HIGHER THAN THE SET SPEED, THE CURRENT TO CRUISE CONTROL ACTUATOR FLOWS FROM TERMINAL 11 OF ECU → TERMINAL 7 OF CRUISE CONTROL ACTUATOR → TERMINAL 6 → TERMINAL 12 OF CRUISE CONTROL ECU. THIS CAUSES THE MOTOR IN THE CRUISE CONTROL ACTUATOR TO ROTATE TO CLOSE THE THROTTLE VALVE AND RETURN THE THROTTLE CABLE TO DECREASE THE VEHICLE SPEED. 3. COAST CONTROL DURING THE CRUISE CONTROL DRIVING, WHILE THE COAST SW IS ON, THE CRUISE CONTROL ACTUATOR RETURNS THE THROTTLE CABLE TO CLOSE THE THROTTLE VALVE AND DECREASE THE DRIVING SPEED. THE VEHICLE SPEED WHEN THE COAST SW IS TURNED OFF IS MEMORIZED AND THE VEHICLE CONTINUES AT THE NEW SET SPEED. 4. ACCEL CONTROL DURING CRUISE CONTROL DRIVING, WHILE THE ACCEL SW IS TURNED ON, THE CRUISE CONTROL ACTUATOR PULLS THE THROTTLE CABLE TO OPEN THE THROTTLE VALVE AND INCREASE THE DRIVING SPEED. THE VEHICLE SPEED WHEN THE ACCEL SW IS TURNED OFF IS MEMORIZED AND THE VEHICLE CONTINUES AT THE NEW SET SPEED. 5. RESUME CONTROL UNLESS THE VEHICLE SPEED FALLS BELOW THE MINIMUM SPEED LIMIT (APPROX. 40 KM/H, 25 MPH) AFTER CANCELING THE SET SPEED BY THE CANCEL SW, PUSHING THE RESUME SW WILL CAUSE THE VEHICLE TO RESUME THE SPEED SET BEFORE CANCELLATION. 6. MANUAL CANCEL MECHANISM IF ANY OF THE FOLLOWING OPERATIONS OCCURS DURING CRUISE CONTROL OPERATION, CURRENT FLOW TO MAGNETIC CLUTCH OF THE ACTUATOR IS CUT TURNS OFF AND THE MOTOR ROTATES TO CLOSE THE THROTTLE VALVE AND THE CRUISE CONTROL IS RELEASED. ∗ PLACING THE SHIFT LEVER IN “N” POSITION (PARK/NEUTRAL POSITION SW (NEUTRAL START SW ON). “SIGNAL INPUT TO TERMINAL 2 OF ECU” (A/T) ∗ DEPRESSING THE CLUTCH PEDAL (CLUCH SW ON). “SIGNAL INPUT TO TERMINAL 2 OF THE ECU” (M/T) ∗ DEPRESSING THE BRAKE PEDAL (STOP LIGHT SW ON). “SIGNAL INPUT TO TERMINAL 16 OF ECU” ∗ PUSH THE CANCEL SW (CANCEL SW ON). “SIGNAL INPUT TO TERMINAL 18 OF ECU” ∗ DEPRESSING THE PARKING BRAKE PEDAL (PARKING BRAKE SW ON). “SIGNAL INPUT TO TERMINAL 3 OF ECU” (3VZ–FE) ∗ PULLING THE PARKING BRAKE LEVER (PARKING BRAKE SW ON). “SIGNAL INPUT TO TERMINAL 3 OF THE ECU” (5S–FE) 196 7. AUTO CANCEL FUNCTION A) IF ANY OF THE FOLLOWING OPERATING CONDITIONS OCCURS DURING CRUISE CONTROL OPERATION, THE SET SPEED IS ERASED, CURRENT FLOW TO MAGNETIC CLUTCH IS CUT OFF AND THE CRUISE CONTROL IS RELEASED. (MAIN SW TURNS OFF). WHEN THIS OCCURS, THE IGNITION SW MUST BE TURNED OFF ONCE BEFORE THE MAIN SW WILL TURN ON AGAIN. ∗ OVER CURRENT TO TRANSISTOR DRIVING MOTOR AND/OR MAGNETIC CLUTCH. ∗ WHEN CURRENT CONTINUED TO FLOW TO THE MOTOR INSIDE THE ACTUATOR IN THE THROTTLE VALVE “OPEN” DIRECTION. ∗ OPEN CIRCUIT IN MOTOR AND/OR MAGNETIC CLUTCH. ∗ MOMENTARY INTERRUPTION OF VEHICLE SPEED SIGNAL. ∗ SHORT CIRCUIT IN CRUISE CONTROL SW. ∗ MOTOR DOES NOT OPERATE DESPITE THE MOTOR DRIVE SIGNAL BEING OUTPUT. B) IF ANY OF THE FOLLOWING CONDITIONS OCCURS DURING CRUISE CONTROL OPERATION, THE SET SPEED IS ERASED AND THE CRUISE CONTROL IS RELEASED. CURRENT FLOW TO MAGNETIC CLUTCH IS CUT OFF UNTIL THE SET SW IS “ON” AGAIN.) ∗ WHEN THE VEHICLE SPEED HAS FALLEN BELOW THE MINIMUM SPEED LIMIT, APPROX. 40 KM/H (25 MPH) ∗ WHEN THE VEHICLE SPEED HAS FALLEN MORE THAN 16 KM/H (10 MPH) BELOW THE SET SPEED, E.G. ON AN UPWARD SLOPE. ∗ WHEN POWER TO THE CRUISE CONTROL SYSTEM IS MOMENTARILY CUT OFF. C) IF ANY OF THE FOLLOWING CONDITIONS OCCURS DURING CRUISE CONTROL OPERATION, THE CRUISE CONTROL IS RELEASED. ∗ OPEN CIRCUIT FOR TERMINAL 1 OF CRUISE CONTROL ECU. 8. AUTOMATIC TRANSMISSION CONTROL FUNCTION ∗ IN OVERDRIVE. IF THE VEHICLE SPEED BECOMES LOWER THAN THE OVERDRIVE CUT SPEED (SET SPEED MINUS APPROX. 4 KM/H, 2.5 MPH) DURING CRUISE CONTROL OPERATION, SUCH AS DRIVING UP A HILL, THE OVERDRIVE IS RELEASED AND THE POWER INCREASED TO PREVENT A REDUCTION IN VEHICLE SPEED. ∗ AFTER RELEASING THE OVERDRIVE, IF VEHICLE SPEED BECOMES HIGHER THAN THE OVERDRIVE RETURN SPEED (SET SPEED MINUS APPROX. 2 KM/H, 1.2 MPH) AND THE ECU JUDGES BY THE SIGNALS FROM POTENTIOMETER OF THE ACTUATOR THAT THE UPWARD SLOPE HAS FINISHED, OVERDRIVE IS RESUMED AFTER A WHILE. SERVICE HINTS C 2 CRUISE CONTROL ACTUATOR 1–3 : APPROX. 2 K
5–4 : APPROX. 38
C13 CRUISE CNTROL SW MAIN [COMB. SW] 15–20 : CONTINUITY WITH MAIN SW ON 20–17 : APPROX. 418
WITH CANCEL SW ON APPROX. 68
WITH RESUME/ACCEL SW ON APPROX. 198
WITH SET/COAST SW ON C16 CRUISE CONTROL ECU 14–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 1,15–GROUND : ALWAYS APPROX. 12 VOLTS 3–GROUND : CONTINUITY WITH PARKING BRAKE SW ON (ONE OF THE CANCEL SW) OR BRAKE LEVEL WARNING SW ON 20–GROUND : 4 PULSE WITH 1 ROTATION OF ROTOR SHAFT 18–GROUND : APPROX. 418
WITH CANCEL SW ON IN CONTROL SW APPROX. 68
WITH RES/ACC SW ON IN CONTROL SW APPROX. 198
WITH SET/COAST SW ON IN CONTROL SW 13–GROUND : ALWAYS CONTINUITY 2–GROUND : CONTINUITY WITH SHIFT LEVER AT N POSITION (A/T) OR CLUTCH PEDAL DEPRESSED (M/T) 197 ELECTRONIC CONTROLLED TRANSMISSION AND A/T INDICATOR (1MZ–FE) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 15A EFI 7. 5A IGN 15A STOP W–B 9 1D 3 1M 2 2B 2 G–R G–W 3 EFI MAIN RELAY 2 A 1 A 5 2 2D 3 2C 4 2D R–Y B–O W–G N2 1 B 12 IP3 1 B G–W G–R 1 2 G–W 15 1A 2 B FROM CRUISE CONTROL ECU IP1 11 B–O B–O IP1 S10 STOP LIGHT SW B–O 6 1M 18 A ,N3 NOISE FILTER (FOR STOP LIGHT) B–O W–L 23 D 22 D 14 D 24 D +B +B1 E7 G–W B–O B–O 4 3B BATT A ,E8 Y–B 19 3C I23 7 D STP B ,E9 C , E10 OD1 D 17 A L–Y V 4 2 3 E01 E02 33 A E03 28 A NC2– E1 16 A O6 O/D DIRECT CLUTCH SPEED SENSOR TO CRUISE CONTROL ECU P–L EB 198 BR W–B E2 ELECTRONIC CONTROLLED TRANSMISSION SOLENOID NC2+ 4 B 9 B 1 2 BR W–B B–O 1 W–B 6 W–B B–O A I18 P–L A J7 JUNCTION CONNECTOR P–L 34 A Y–L S2 11 A W–L S1 27 A Y–L SL 3 A Y–G ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) SLN– ED FROM POWER SOURCE SYSTEM (SEE PAGE 64) 10A GAUGE BR BR 6 1D BR I18 R–L L–R 3 6 J3 JUNCTION CONNECTOR C R–L R–L L–R C 32 A 7 B IDL A ,E8 B ,E9 C , E10 VTA 1 B 3 IN1 R–L L–R IN1 I18 3 TO COMBINATION METER L–R NORMAL 6 POWER BR L–W G L E6 ELECTRONIC CONTROLLED TRANSMISSION PATTERN SELECT SW B–Y I18 L–R 6 E7 II1 C 4 L–W 2 L–W THW L–R II2 R–L 4 2 20 B I6 L–R FROM CRUISE CONTROL ECU FROM COOLING FAN ECU E4 ENGINE COOLANT TEMP. SENSOR (EFI WATER TEMP. SENSOR) 1 L–R 8 1K T1 THROTTLE POSITION SENSOR 1 R–L 22 B 3 D E2 P VC D ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) TE1 12 D 6 D G–O 10 3D D D GR–B IP1 8 TE2 TE1 4 C8 COMBINATION METER SPEED 5 12 D1 DATA LINK CONNECTOR 1 (CHECK CONNECTOR) 11 G G–B E1 BR G–O V–Y 2 3 G–O J1 JUNCTION CONNECTOR 22 3D G–W 1 OD2 SP1 5 C G–W 11 D V–Y TE2 IP3 14 IP3 A J7 JUNCTION CONNECTOR LG BR P A 2 3 V5 VEHICLE SPEED SENSOR (SPEED SENSOR) 1 R–L 199 ELECTRONIC CONTROLLED TRANSMISSION AND A/T INDICATOR (1MZ–FE) * 1 : W/ A/T INDICATOR LIGHT R–L 2 IP3 R–L R–L TO GENERATOR (ALTERNATOR) R–L I18 R–L L–R P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW (NEUTRAL START SW)] 2 R–L 2 D N R P 4 3 10 9 8 7 G–W 13 IQ1 R–B 14 IQ1 8 IQ1 1 IP3 9 IQ1 R–B O 7 IQ1 TO BACK–UP LIGHT I18 R–B Y–L R O B–O 13 IP1 I18 O Y–L Y–L 6 IP1 O Y–L L 15 D 2 R I19 R–B 10 D L R–B 2 D L 5 2 D C11 A/T INDICATOR LIGHT [COMB. METER] 4 N 6 (* 1) 9 G–O 7 (* 1) II1 10 W–B 2 11 POWER 13 O/D 8 B G–O I6 G–O 1 W–B J2 JUNCTION CONNECTOR B B W–B O5 O/D MAIN SW 3 200 IF (* 1) G–W R–B G–O R–L II1 R–B 5 (* 1) R (* 1) (* 1) B–O O (* 1) (* 1) Y–L (* 1) L–R (* 1) E 7 B , E 8 C , E10 A ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) R–L I1 3 R P SYSTEM OUTLINE PREVIOUS AUTOMATIC TRANSMISSIONS HAVE SELECTED EACH GEAR SHIFT USING MECHANICALLY CONTROLLED THROTTLE HYDRAULIC PRESSURE, GOVERNOR HYDRAULIC PRESSURE AND LOCK–UP HYDRAULIC PRESSURE. THE ELECTRONIC CONTROLLED TRANSMISSION, HOWEVER, ELECTRICALLY CONTROLS THE LINE PRESSURE AND LOCK–UP PRESSURE ETC., THROUGH THE SOLENOID VALVE. ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) CONTROL OF THE SOLENOID VALVE BASED ON THE INPUT SIGNALS FROM EACH SENSOR MAKES SMOOTH DRIVING POSSIBLE BY SHIFT SELECTION FOR EACH GEAR WHICH IS MOST APPROPRIATE TO THE DRIVING CONDITIONS AT THAT TIME. 1. GEAR SHIFT OPERATION DURING DRIVING, THE ENGINE CONTROL MODULE (ECU) SELECTS THE SHIFT FOR EACH GEAR WHICH IS MOST APPROPRIATE TO THE DRIVING CONDITIONS, BASED ON INPUT SIGNALS FROM THE ENGINE COOLANT TEMP. SENSOR (EFI WATER TEMP. SENSOR) TO TERMINAL THW OF THE ENGINE CONTROL MODULE (ECU), AND ALSO THE INPUT SIGNALS TO TERMINAL NC2+ OF THE ENGINE CONTROL MODULE (ECU) FROM THE VEHICLE SPEED SENSOR (SPEED SENSOR) DEVOTED TO THE ELECTRONIC CONTROLLED TRANSMISSION. CURRENT IS THEN OUTPUT TO THE ELECTRONIC CONTROLLED TRANSMISSION SOLENOIDS. WHEN SHIFTING TO 1ST SPEED, CURRENT FLOWS FROM TERMINAL S1 OF THE ENGINE CONTROL MODULE (ECU) → TERMINAL 3 OF THE ELECTRONIC CONTROLLED TRANSMISSION SOLENOIDS → GROUND, AND CONTINUITY TO THE NO. 1 SOLENOID CAUSES THE SHIFT. FOR 2ND SPEED, CURRENT FLOWS FROM TERMINAL S1 OF THE ENGINE CONTROL MODULE (ECU) → TERMINAL 3 OF THE ELECTRONIC CONTROLLED TRANSMISSION SOLENOIDS → GROUND, AND FROM TERMINAL S2 OF THE ENGINE CONTROL MODULE (ECU) → TERMINAL 1 OF THE ELECTRONIC CONTROLLED TRANSMISSION SOLENOIDS → GROUND, AND CONTINUITY TO SOLENOIDS NO. 1 AND NO. 2 CAUSES THE SHIFT. FOR 3RD SPEED, THERE IS NO CONTINUITY TO NO. 1 SOLENOID, ONLY TO NO. 2, CAUSING THE SHIFT. SHIFTING INTO 4TH SPEED (OVERDRIVE) TAKES PLACE WHEN THERE IS NO CONTINUITY TO EITHER NO. 1 OR NO. 2 SOLENOID. 2. LOCK–UP OPERATION WHEN THE ENGINE CONTROL MODULE (ECU) JUDGES FROM EACH SIGNAL THAT LOCK–UP OPERATION CONDITIONS HAVE BEEN MET, CURRENT FLOWS FROM TERMINAL SL OF THE ENGINE CONTROL MODULE (ECU) → TERMINAL 2 OF THE ELECTRONIC CONTROLLED TRANSMISSION SOLENOID → GROUND, CAUSING CONTINUITY TO THE LOCK–UP SOLENOID AND CAUSING LOCK–UP OPERATION. 3. STOP LIGHT SW CIRCUIT IF THE BRAKE PEDAL IS DEPRESSED (STOP LIGHT SW ON) WHEN DRIVING IN LOCK–UP CONDITION, A SIGNAL IS INPUT TO TERMINAL STP OF THE ENGINE CONTROL MODULE (ECU), THE ENGINE CONTROL MODULE (ECU) OPERATES AND CONTINUITY TO THE LOCK–UP SOLENOID IS CUT. 4. OVERDRIVE CIRCUIT * O/D MAIN SW ON WHEN THE O/D MAIN SW IS TURNED ON (O/D OFF INDICATOR LIGHT TURNS OFF), A SIGNAL IS INPUT TO TERMINAL OD2 OF THE ENGINE CONTROL MODULE (ECU) AND ENGINE CONTROL MODULE (ECU) OPERATION CAUSES GEAR SHIFT WHEN THE CONDITIONS FOR OVERDRIVE ARE MET. * O/D MAIN SW OFF WHEN THE O/D MAIN SW IS TURNED TO OFF, THE CURRENT FLOWING THROUGH THE O/D OFF INDICATOR LIGHT FLOWS THROUGH THE O/D MAIN SW TO GROUND. CAUSING THE INDICATOR LIGHT TO LIGHT UP. AT THE SAME TIME, A SIGNAL IS INPUT TO TERMINAL OD2 OF THE ENGINE CONTROL MODULE (ECU) AND ENGINE CONTROL MODULE (ECU) OPERATION PREVENTS SHIFT INTO OVERDIRVE. 5. ELECTRONIC CONTROLLED TRANSMISSION PATTERN SELECT SW CIRCUIT IF THE ELECTRONIC CONTROLLED TRANSMISSION PATTERN SELECT SW IS CHANGED FROM NORMAL TO POWER, THE CURRENT FLOWING THROUGH THE POWER INDICATOR FLOWS TO GROUND, CURRENT FLOWS TO TERMINAL P OF THE ENGINE CONTROL MODULE (ECU), THE ENGINE CONTROL MODULE (ECU) OPERATES, AND SHIFT UP AND SHIFT DOWN OCCUR AT HIGHER VEHICLE SPEEDS THAN WHEN THE SW IS IN NORMAL POSITION. 201 ELECTRONIC CONTROLLED TRANSMISSION AND A/T INDICATOR (1MZ–FE) SERVICE HINTS E 7(B), E 8 (C), E10(A) ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) (TURN ON THE IGNTION SW) S1, S2– E1 : 9.0–14.0 VOLTS WITH SOLENOID ON 0–1.5 VOLTS WITH SOLENOID OFF P– E1 : 7.5–14.0 VOLTS WITH IGNITION SW ON AND PATTERN SELECT SW AT POWER POSITION L– E1 : 7.5–14.0 VOLTS WITH SHIFT LEVER AT L POSITION 2– E1 : 7.5–14.0 VOLTS WITH SHIFT LEVER AT 2 POSITION R– E1 : 7.5–14.0 VOLTS WITH SHIFT LEVER AT R POSITION STP– E1 : 9.0–14.0 VOLTS WITH BRAKE PEDAL DEPRESSED THW– E2 : 0.2–1.0 VOLTS WITH WITH ENGINE COOLANT TEMP. 60°C (140°F) –120°C (248°F) IDL– E2 : 0–1.5 VOLTS WITH THROTTLE VALVE FULLY CLOSED 9.0–14.0 VOLTS WITH THROTTLE VALVE FULLY OPENED VTA–E2 : 0.3–0.8 VOLTS WITH THROTTLE VALVE FULLY CLOSED 3.2–4.9 VOLTS WITH THROTTLE VALVE FULLY OPENED VC– E2 : 4.5–5.5 VOLTS WITH IGNITION SW AT ON POSITION OD1– E1 : 4.5–5.5 VOLTS WITH IGNITION SW AT ON POSITION OD2– E1 : 9.0–14.0 VOLTS WITH O/D MAIN SW TURNED OFF 0–3.0 VOLTS WITH O/D MAIN SW TURNED ON IGSW– E1 : 9.0–14.0 VOLTS WITH IGNITION SW AT ON POSITION +B– E1 : 9.0–14.0 VOLTS WITH IGNITION SW AT ON POSITION +B1– E1 : 9.0–14.0 VOLTS WITH IGNITION SW AT ON POSITION E 2 ELECTRONIC CONTROLLED TRANSMISSION SOLENOID 1, 2, 6–GROUND : EACH 11–15 Ω O 5 O/D MAIN SW 1–3 : CLOSED WITH O/D MAIN SW OFF, OPEN WITH O/D MAIN SW ON : PARTS LOCATION CODE SEE PAGE CODE C8 32 E9 C11 32 E10 D1 28 J1 E2 28 E4 E6 SEE PAGE O5 33 D 32 O6 29 33 P1 29 J2 33 S10 33 28 J3 33 T1 29 32 J7 33 V5 29 A 32 N2 A 33 E8 B 32 N3 B 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1A 1D 1K 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 22 ENGINE ROOM MAIN WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 22 ENGINE WIRE AND J/B NO NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO. 3 (BEHIND COMBINATION METER) 1M 2B 2C 2D 3B 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) II1 42 COWL WIRE AND INSTRUMENT PANEL WIRE II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE IN1 42 INSTRUMENT PANEL WIRE AND SWITCH WIRE 44 ENGINE WIRE AND COWL WIRE 44 ENGINE WIRE AND INSTRUMENT PANEL WIRE IP1 IP3 IQ1 : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION EB 38 (1MZ–FE) FRONT LEFT FENDER ED 38 (1MZ–FE) INTAKE MANIFOLD LH IF 42 LEFT KICK PANEL 202 SEE PAGE 32 E7 CODE CODE C : SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS CODE I1 44 COWL WIRE I19 I6 44 INSTRUMENT PANEL WIRE I23 I18 44 ENGINE WIRE SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS COWL WIRE 203 ELECTRONIC CONTROLLED TRANSMISSION AND A/T INDICATOR (5S–FE) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 3 1M B–O 9 1D G–R 1 B G–R 2 2B 3 2C W–G B–O IP1 12 1 R BR R 2 15 1A IP3 B–O I18 BR E18 BR E17 I18 B1 (* 3) BR 13 A B BR 12 A 1 B 11 B 9 B 16 B G–W B–O B–O 4 3B B I23 R W–L 19 3C B–W 11 3 1 G–W W–B 6 1M 4 2D 4 BR 5 2 L 2 G–W EFI MAIN RELAY FROM IGNITION SW ” ST1” 3 S10 STOP LIGHT SW 1 N2 2 2D BR 2 B G–W B 1 A A ,N3 2 A NOISE FILTER (FOR STOP LIGHT) T1 THROTTLE POSITION SENSOR IP1 B–O 18 G–W FROM MANIFOLD ABSOLUTE PRESSURE SENSOR (VACUUM SENSOR) 15A STOP 15A EFI TO MANIFOLD ABSOLUTE PRESSURE SENSOR (VACUUM SENSOR) 7. 5A IGN 1 A 4 A BATT 22 A B/K 12 B NSW IDL VC VTA E2 E21 ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) E 7 C , E 8 B , E 10 A S2 S1 SL E1 15 C 2 C 1 C 14 C E01 13 C SP1 E02 9 A 26 C V–Y 22 3D 10 3D V–Y 4 C8 COMBINATION METER W 5 12 IP3 G 14 IP3 LG 11 P W–B W–B BR 1 B NO. 3 (LOCK–UP) NO. 1 NO. 2 E2 A ,E3 B ELECTRONIC CONTROLLED TRANSMISSION SOLENOID G–B V 3 A L–Y P–L 1 A B SPEED 2 3 V5 VEHICLE SPEED SENSOR (SPEED SENSOR) 1 R–L W–B BR BR EB 204 EC BR ED 16 IP3 BR * 1 : W/ A/T INDICATOR LIGHT * 2 : W/O A/T INDICATOR LIGHT * 3 : EX. CALIFORNIA FROM POWER SOURCE SYSTEM (SEE PAGE 64) 10A GAUGE J3 JUNCTION CONNECTOR C C R–L R–L C R–L I18 R–L P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW (NEUTRAL START SW)] L–R L 2 D N R P 4 3 10 9 8 7 Y–L I18 1 IP3 R–L L–R 6 IP1 G–W Y–L R–B I6 TO COMBINATION METER 13 O I18 I1 R–B G–O E1 R–B 7 5 4 3 (* 1) G–W 9 IQ1 (* 1) II1 R–B 5 (* 1) R 10 (* 1) B–O O 11 (* 1) O 13 P R N D 2 L POWER G–O O/D OFF C11 A/T INDICATOR LIGHT [COMB. METER] 9 6 9 TT (* 1) 5 W–B D (* 1) D1 DATA LINK CONNECTOR 1 (CHECK CONNECTOR) TT J1 JUNCTION CONNECTOR D BR–B BR–B 17 D IP1 G–O 15 8 13 IQ1 7 A E 7 C , E 8 B , E10 A ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) BR–B G–O BR–B I18 OD2 14 IQ1 TO BACK–UP LIGHT TT 7 B Y–L 2 (* 1) L 8 IQ1 Y–L P THW 7 IQ1 (* 1) 18 A L–R 19 A (* 1) O 6 A LG Y–L 2 R–L L–R IP1 R–B (* 2) R B–O L–R I13 4 B ECT 2 II1 E1 3 BR 3 R–L TO GENERATOR (ALTERNATOR) L–R L–R E4 ENGINE COOLANT TEMP. SNESOR (EFI WATER TEMP. SENSOR) BR 1 R–L IP3 2 3 IN1 L–R II1 2 R–L O 3 6 8 1K 4 II2 NORMAL 6 R–L R–L 6 IN1 R–L POWER E6 ELECTRONIC CONTROLLED TRANSMISSION PATTERN SELECT SW 6 1D D3 DATA LINK CONNECTOR 2 (TDCL) G–O I6 G–O O5 O/D MAIN SW 1 3 B W–B J2 JUNCTION CONNECTOR B B R–L BR 12 3D 3 3D W–B BR IF 205 ELECTRONIC CONTROLLED TRANSMISSION AND A/T INDICATOR (5S–FE) SYSTEM OUTLINE PREVIOUS AUTOMATIC TRANSMISSIONS HAVE SELECTED EACH GEAR SHIFT USING MECHANICALLY CONTROLLED THROTTLE HYDRAULIC PRESSURE, GOVERNOR HYDRAULIC PRESSURE AND LOCK–UP HYDRAULIC PRESSURE. THE ELECTRONIC CONTROLLED TRANSMISSION, HOWEVER, ELECTRICALLY CONTROLS THE LINE PRESSURE AND LOCK–UP PRESSURE ETC., THROUGH THE SOLENOID VALVE. ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) CONTROL OF THE SOLENOID VALVE BASED ON THE INPUT SIGNALS FROM EACH SENSOR MAKES SMOOTH DRIVING POSSIBLE BY SHIFT SELECTION FOR EACH GEAR WHICH IS MOST APPROPRIATE TO THE DRIVING CONDITIONS AT THAT TIME. 1. GEAR SHIFT OPERATION DURING DRIVING, THE ENGINE CONTROL MODULE (ECU) SELECTS THE SHIFT FOR EACH GEAR WHICH IS MOST APPROPRIATE TO THE DRIVING CONDITIONS, BASED ON INPUT SIGNALS FROM THE ENGINE COOLANT TEMP. SENSOR (EFI WATER TEMP. SENSOR) TO TERMINAL THW OF THE ENGINE CONTROL MODULE (ECU), AND ALSO THE INPUT SIGNALS TO TERMINAL SP1 OF THE ENGINE CONTROL MODULE (ECU) FROM THE VEHICLE SPEED SENSOR (SPEED SENSOR) DEVOTED TO THE ELECTRONIC CONTROLLED TRANSMISSION. CURRENT IS THEN OUTPUT TO THE ELECTRONIC CONTROLLED TRANSMISSION SOLENOIDS. WHEN SHIFTING TO 1ST SPEED, CURRENT FLOWS FROM TERMINAL S1 OF THE ENGINE CONTROL MODULE (ECU) → TERMINAL (A)3 OF THE ELECTRONIC CONTROLLED TRANSMISSION SOLENOIDS → GROUND, AND CONTINUITY TO THE NO. 1 SOLENOID CAUSES THE SHIFT. FOR 2ND SPEED, CURRENT FLOWS FROM TERMINAL S1 OF THE ENGINE CONTROL MODULE (ECU) → TERMINAL (A)3 OF THE ELECTRONIC CONTROLLED TRANSMISSION SOLENOIDS → GROUND, AND FROM TERMINAL S2 OF THE ENGINE CONTROL MODULE (ECU) → TERMINAL (A)1 OF THE ELECTRONIC CONTROL TRANSMISSION SOLENOIDS → GROUND, AND CONTINUITY TO SOLENOIDS NO. 1 AND NO. 2 CAUSES THE SHIFT. FOR 3RD SPEED, THERE IS NO CONTINUITY TO NO. 1 SOLENOID, ONLY TO NO. 2, CAUSING THE SHIFT. SHIFTING INTO 4TH SPEED (OVERDRIVE) TAKES PLACE WHEN THERE IS NO CONTINUITY TO EITHER NO. 1 OR NO. 2 SOLENOID. 2. LOCK–UP OPERATION WHEN THE ENGINE CONTROL MODULE (ECU) JUDGES FROM EACH SIGNAL THAT LOCK–UP OPERATION CONDITIONS HAVE BEEN MET, CURRENT FLOWS FROM TERMINAL SL OF THE ENGINE CONTROL MODULE (ECU) → TERMINAL (B)1 OF THE ELECTRONIC CONTROLLED TRANSMISSION SOLENOID → GROUND, CAUSING CONTINUITY TO THE LOCK–UP SOLENOID AND CAUSING LOCK–UP OPERATION. 3. STOP LIGHT SW CIRCUIT IF THE BRAKE PEDAL IS DEPRESSED (STOP LIGHT SW ON) WHEN DRIVING IN LOCK–UP CONDITION, A SIGNAL IS INPUT TO TERMINAL B/K OF THE ENGINE CONTROL MODULE (ECU), THE ENGINE CONTROL MODULE (ECU) OPERATES AND CONTINUITY TO THE LOCK–UP SOLENOID IS CUT. 4. OVERDRIVE CIRCUIT * O/D MAIN SW ON WHEN THE O/D MAIN SW IS TURNED ON (O/D OFF INDICATOR LIGHT TURNS OFF), A SIGNAL IS INPUT TO TERMINAL OD2 OF THE ENGINE CONTROL MODULE (ECU) AND ENGINE CONTROL MODULE (ECU) OPERATION CAUSES GEAR SHIFT WHEN THE CONDITIONS FOR OVERDRIVE ARE MET. * O/D MAIN SW OFF WHEN THE O/D MAIN SW IS TURNED TO OFF, THE CURRENT FLOWING THROUGH THE O/D OFF INDICATOR LIGHT FLOWS THROUGH THE O/D MAIN SW TO GROUND. CAUSING THE INDICATOR LIGHT TO LIGHT UP. AT THE SAME TIME, A SIGNAL IS INPUT TO TERMINAL OD2 OF THE ENGINE CONTROL MODULE (ECU) AND ENGINE CONTROL MODULE (ECU) OPERATION PREVENTS SHIFT INTO OVERDRIVE. 5. ELECTRONIC CONTROLLED TRANSMISSION PATTERN SELECT SW CIRCUIT IF THE ELECTRONIC CONTROLLED TRANSMISSION PATTERN SELECT SW IS CHANGED FROM NORMAL TO POWER, THE CURRENT FLOWING THROUGH THE POWER INDICATOR FLOWS TO GROUND, CURRENT FLOWS TO TERMINAL P OF THE ENGINE CONTROL MODULE (ECU), THE ENGINE CONTROL MODULE (ECU) OPERATES, AND SHIFT UP AND SHIFT DOWN OCCUR AT HIGHER VEHICLE SPEEDS THAN WHEN THE SW IS IN NORMAL POSITION. SERVICE HINTS E 7(C), E 8 (B), E10(A) ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) (TURN ON THE IGNTION SW) S1, S2 –E1 : 9.0–14.0 VOLTS WITH SOLENOID ON 0–1.5 VOLTS WITH SOLENOID OFF P –E1 : 7.5–14.0 VOLTS WITH IGNITION SW ON AND PATTERN SELECT SW AT POWER POSITION L– E1 : 7.5–14.0 VOLTS WITH SHIFT LEVER AT L POSITION 2– E1 : 7.5–14.0 VOLTS WITH SHIFT LEVER AT 2 POSITION R– E1 : 7.5–14.0 VOLTS WITH SHIFT LEVER AT R POSITION B/K– E1 : 9.0–14.0 VOLTS WITH BRAKE PEDAL DEPRESSED THW– E2 : 0.2–1.0 VOLTS WITH WITH ENGINE COOLANT TEMP. 60°C (140°F) –120°C (248°F) IDL– E2 : 0–1.5 VOLTS WITH THROTTLE VALVE FULLY CLOSED 9.0–14.0 VOLTS WITH THROTTLE VALVE FULLY OPENED 206 SERVICE HINTS VTA–E2 : 0.3–0.8 VOLTS WITH THROTTLE VALVE FULLY CLOSED 3.2–4.9 VOLTS WITH THROTTLE VALVE FULLY OPENED VC– E2 : 4.5–5.5 VOLTS WITH IGNITION SW AT ON POSITION OD2– E1 : 9.0–14.0 VOLTS WITH O/D MAIN SW TURNED ON 0–3.0 VOLTS WITH O/D MAIN SW TURNED OFF IGSW– E1 : 9.0–14.0 VOLTS WITH IGNITION SW AT ON POSITION +B– E1 : 9.0–14.0 VOLTS WITH IGNITION SW AT ON POSITION +B1– E1 : 9.0–14.0 VOLTS WITH IGNITION SW AT ON POSITION M–REL– E1 : 9.0–14.0 VOLTS WITH IGNITION SW AT ON POSITION E 2(A), E 3(B) ELECTRONIC CONTROLLED TRANSMISSION SOLENOID (A)1, (A)3, (B)1–GROUND : EACH 11–15 Ω O 5 O/D MAIN SW 1–3 : CLOSED WITH O/D MAIN SW OFF, OPEN WITH O/D MAIN SW ON : PARTS LOCATION CODE SEE PAGE CODE C8 32 C11 32 E7 D1 30 E8 D3 32 E10 SEE PAGE E6 CODE SEE PAGE 32 N2 A 33 C 32 N3 B 32 O5 B 33 33 A 32 P1 31 E2 A 30 J1 33 S10 33 E3 B 30 J2 33 T1 31 30 J3 33 V5 31 E4 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1A 1D 1K 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 22 ENGINE ROOM MAIN WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 22 ENGINE WIRE AND J/B NO NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO. 3 (BEHIND COMBINATION METER) 1M 2B 2C 2D 3B 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) II1 42 COWL WIRE AND INSTRUMENT PANEL WIRE II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE IN1 42 INSTRUMENT PANEL WIRE AND SWITCH WIRE 44 ENGINE WIRE AND COWL WIRE 44 ENGINE WIRE AND INSTRUMENT PANEL WIRE IP1 IP3 IQ1 : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION EB 40 (5S–FE) FRONT LEFT FENDER EC 40 (5S–FE) INTAKE MANIFOLD RH ED 40 (5S–FE) INTAKE MANIFOLD LH IF 42 LEFT KICK PANEL : SPLICE POINTS CODE E17 SEE PAGE WIRE HARNESS WITH SPLICE POINTS 40 (5S–FE) (5S FE) ENGINE WIRE I1 44 COWL WIRE I6 44 INSTRUMENT PANEL WIRE E18 CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS I13 44 COWL WIRE I18 44 ENGINE WIRE I23 44 COWL WIRE 207 ELECTRONIC CONTROLLED TRANSMISSION AND A/T INDICATOR (5S–FE) 208 ABS (ANTI–LOCK BRAKE SYSTEM) (TMC MADE) 209 ABS (ANTI–LOCK BRAKE SYSTEM) (TMC MADE) 60A ABS FROM POWER SOURCE SYSTEM (SEE PAGE 64) F18 FUSE BOX R–L R–L W–L 1 3 EC1 W–L W–L E4 6 A G–W W–L 7 EC1 A6 B , A7 A ABS RELAY 1 B 2 A 4 A A4 A , A5 B ABS ACTUATOR 2 A 5 A 3 B 1 A 13 A 26 A 14 A 18 A 6 A W–R E6 W–B W–B 23 A 24 A 11 A R– SR SFR W–B MR SFL SRR SRL AST A , A 14 B A13 ABS ECU FL+ FSS 10 A FR– FR+ 3 A 16 A BR 9 A R FL– 22 A G W–B GND 15 A W–B E 2 A (SHIELDED) E4 IR2 7 IR2 5 IR2 B 6 W BR I25 R G W–B (SHIELDED) 1 2 W–B A8 ABS SPEED SENSOR FRONT LH EA 210 1 2 A9 ABS SPEED SENSOR FRONT RH MT 1 B W–B 6 A W–R 3 A R–W W 4 A R 1 A G–R 4 B L–R 5 A G–W 1 A L–W 3 B GR–G GR–L W–R 2 B 4 B GR–R W–B M * 1 : USA * 2 : CANADA FROM POWER SOURCE SYSTEM (SEE PAGE 64) 10A GAUGE 15A STOP 15A ECU–IG 15A ECU–B R–L R–L LG–R B–R L–Y B A , N3 NOISE FILTER (FOR STOP LIGHT) 15 3C 2 3B 1 L–Y 2 19 3C 1 IR2 4 IR2 IR2 TC 15 B 13 B 6 B TS W L–Y G–W 5 A D/G 7 3C G–B LG–R 13 3C 4 B 11 3B B–R 2 12 3C 1 B 16 3C B–R G–B R–G 17 3C 3 3C 3 2G G–R C 9 A , C10 B LG–R G–B 4 B R–L 16 3D 15 1A 2 B G–R 6 1M 6 A 17 3D 7 1A 1 A G–W IP3 S10 STOP LIGHT SW 3 G–W IP1 2 A C ABS WARNING LIGHT [COMB. METER] 3 IP3 J1 JUNCTION CONNECTOR R–L 22 8 3 1M G–W C WA R–Y TS 16 Y–B C TC 11 R–G Y–B C 6 1B SHORT PIN LG–R TC 4 D3 J3 DATA LINK JUNCTION CONNECTOR 2 CONNECTOR (TDCL) ABS 14 WB N2 D1 DATA LINK CONNECTOR 1 (CHECK CONNECTOR) 23 12 A 25 A STP A13 A , A14 IG1 BAT B ABS ECU RL+ RSS 7 B RR– RR+ 16 B PKB 8 B 14 B (SHIELDED) (* 2) W (* 1) Y (* 2) B BR 3 3B 8 3C 19 IJ1 6 IJ1 4 IS1 5 IS1 6 8 3D IS1 R–W Y BR R R–W (SHIELDED) (SHIELDED) (1MZ–FE) IJ1 G 4 1 A19 ABS SPEED SENSOR REAR LH 2 II1 1 A20 ABS SPEED SENSOR REAR RH R–W 2 P2 PARKING BRAKE SW 12 1 1 P3 PARKING BRAKE SW BR I21 (* 1) BR BR I21 R G (SHIELDED) R–W BR 9 B (5S–FE) RL– 1 B 211 ABS (ANTI–LOCK BRAKE SYSTEM) (TMC MADE) SYSTEM OUTLINE THIS SYSTEM CONTROLS THE RESPECTIVE BRAKE FLUID PRESSURES ACTING ON THE DISC BRAKE CYLINDERS OF THE RIGHT FRONT WHEEL, LEFT FRONT WHEEL AND REAR WHEELS WHEN THE BRAKES ARE APPLIED IN A PANIC STOP SO THAT THE WHEELS DO NOT LOCK. THIS RESULTS IN IMPROVED DIRECTIONAL STABILITY AND STEERABILITY DURING PANIC BRAKEING. 1. INPUT SIGNALS (1) SPEED SENSOR SIGNAL THE SPEED OF THE WHEELS IS DETECTED AND INPUT TO TERMINALS FL+, FR+, RL+ AND RR+ OF THE ABS ECU. (2) STOP LIGHT SW SIGNAL A SIGNAL IS INPUT TO TERMINAL STP OF THE ABS ECU WHEN BRAKE PEDAL IS OPERATED. (3) PARKING BRAKE SW SIGNAL A SIGNAL IS INPUT TO TERMINAL PKB OF THE ABS ECU WHEN THE PARKING BRAKE IS OPERATED. 2. SYSTEM OPERATION DURING SUDDEN BRAKEING THE ABS ECU, WHICH HAS SIGNALS INPUT FROM EACH SENSOR, CONTROLS THE CURRENT FLOWING TO THE SOLENOID INSIDE THE ACTUATOR AND LETS THE HYDRAULIC PRESSURE ACTING ON EACH WHEEL CYLINDER ESCAPE TO THE RESERVOIR. THE PUMP INSIDE THE ACTUATOR IS ALSO OPERATING AT THIS TIME AND IT RETURNS THE BRAKE FLUID FROM THE RESERVOIR TO THE MASTER CYLINDER, THUS PREVENTING LOCKING OF THE VEHICLE WHEELS. IF THE ECU JUDGES THAT THE HYDRAULIC PRESSURE ACTING ON THE WHEEL CYLINDER IS INSUFFICIENT, THE CURRENT ACTING ON THE SOLENOID IS CONTROLLED AND THE HYDRAULIC PRESSURE IS INCREASED. HOLDING OF THE HYDRAULIC PRESSURE IS ALSO CONTROLLED BY THE ECU, BY THE SAME METHOD AS ABOVE. BY REPEATED PRESSURE REDUCTION, HOLDING AND INCREASE ARE REPLATED TO MAINTAIN VEHICLE STABILITY AND TO IMPROVE STEERBILITY DURING SUDDEN BRAKING. SERVICE HINTS A 4(A), A 5(B) ABS ACTUATOR (A)1, (A)3, (A)4, (A)6 – (A)2 : APPROX. 6 Ω (A)2–GROUND : APPROX. 5 Ω A 6(B), A 7(A) ABS RELAY (A)1–(B) 3 : 60 Ω–100 Ω (A)4–(B) 3 : 60 Ω–100 Ω (A)1, (B) 2–GROUND : APPROX. 12 VOLTS (A)6–GROUND : APPROX. 12 VOLTS A 8, A 9 ABS SPEED SENSOR FRONT LH, RH 1–2 : 0.8 K–1.3 KΩ A19, A20 ABS SPEED SENSOR REAR LH, RH 1–2 : 1.1 K–1.5 KΩ A13(A), A14(B) ABS ECU (CONNECT THE ECU CONNECTORS) (A) 5–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION AND DATA LINK CONNECTOR 1 (CHECK CONNECTOR) TS–EI NOT CONNECTED (B)15–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION AND DATA LINK CONNECTOR 1 (CHECK CONNECTOR) TS–EI NOT CONNECTED (A) 1–GROUND, (A) 13–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION AND ABS WARNING LIGHT GOES OFF (A)14–GROUND, (A) 1–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION AND ABS WARNING LIGHT GOES OFF (A)26–GROUND, (A) 18–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION AND ABS WARNING LIGHT GOES OFF (A) 2–GROUND : ALWAYS CONTINUITY (A)15–GROUND : ALWAYS CONTINUITY (A)12–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION (B) 6–GROUND : APPROX. 12 VOLTS WITH BRAKE PEDAL DEPRESSED (A)25–GROUND : ALWAYS APPROX. 12 VOLTS 212 : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE A19 CODE 34 SEE PAGE A4 A 28 (1MZ–FE), 30 (5S–FE) A5 B 28 (1MZ–FE), 30 (5S–FE) 34 N2 A 33 A6 B 28 (1MZ–FE), 30 (5S–FE) C9 A 32 N3 B 33 A7 A 28 (1MZ–FE), 30 (5S–FE) C10 B 32 P2 33 A20 J3 33 A8 28 (1MZ–FE), 30 (5S–FE) D1 28 (1MZ–FE), 30 (5S–FE) P3 33 A9 28 (1MZ–FE), 30 (5S–FE) D3 32 S10 33 A13 A 32 F10 28 (1MZ–FE), 30 (5S–FE) A14 B 32 J1 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1A 1B 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO. 3 (BEHIND COMBINATION METER) 1M 2G 3B 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE EC1 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ENGINE WIRE AND ENGINE ROOM MAIN WIRE II1 42 COWL WIRE AND INSTRUMENT PANEL WIRE IJ1 42 FLOOR NO. 1 WIRE AND COWL WIRE IP3 44 ENGINE WIRE AND COWL WIRE IR2 44 ENGINE ROOM MAIN WIRE AND COWL WIRE IS1 44 FLOOR NO. 2 WIRE AND COWL WIRE : GROUND POINTS CODE EA SEE PAGE 38 (1MZ–FE) 40 (5S–FE) GROUND POINTS LOCATION FRONT RIGHT FENDER : SPLICE POINTS CODE E4 E6 SEE PAGE WIRE HARNESS WITH SPLICE POINTS 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) ENGINE ROOM MAIN WIRE CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS E6 40 (5S–FE) ENGINE ROOM MAIN WIRE I21 44 COWL WIRE I25 44 ENGINE ROOM MAIN WIRE 213 ABS (ANTI–LOCK BRAKE SYSTEM) (TMM MADE) F18 FUSE BOX 60A ABS FROM POWER SOURCE SYSTEM (SEE PAGE 64) 15A STOP 15A ECU–IG 1 3 1M 2 A 6 1M B–R G–R G–W 7 1A 1 A N2 A 16 3C ,N3 B NOISE FILTER (FOR STOP LIGHT) 2 B 1 B 15 3C B–R 2 G–W 7 3C 1 G–R W–L 19 3C S10 STOP LIGHT SW G–W G–W 15 1A 1 IR2 B–R IR1 G–W 19 W–L 7 EC1 1 B 9 A 2 B +BS STP IG A4 A , A5 B ABS ACTUATOR AND ECU FR+ FR– 11 A 5 A FL+ FL– 13 A 7 A R G (SHIELDED) I14 (SHIELDED) W–B W–B IR2 6 IR2 5 IR2 B W W–B 7 (SHIELDED) W–B R G I21 6 2 1 A9 ABS SPEED SENSOR FRONT RH 214 2 1 A8 ABS SPEED SENSOR FRONT LH IJ1 FROM POWER SOURCE SYSTEM (SEE PAGE 64) D1 DATA LINK CONNECTOR 1 (CHECK CONNECTOR) D3 DATA LINK CONNECTOR 2 (CHECK CONNECTOR) TS IP3 3 WA 23 R–G Y–B 8 C WB 16 LG–R 11 IP1 6 1B 22 3 EC1 3 R–L TC 4 IP3 C G–B J3 JUNCTION CONNECTOR C G–B I13 G–B Y–B LG–R C J1 JUNCTION CONNECTOR R–L TC SHORT PIN G–B ABS 10A GAUGE G–W 14 16 3D 6 A 3 3C C9 G–W R–G 17 3D A , C10 B ABS WARNING LIGHT (COMB. LIGHT) 13 3C 12 3C 4 B G–B LG–R 17 3C G–B 12 IR1 4 IR2 12 A 15 A 3 B 1 A TC TS LP W A4 G–B R–G IR2 LG–R 2 A ,A5 B ABS ACTUATOR AND ECU RR– GND 14 A 4 B (SHIELDED) W–B B R RR+ 6 A W RL– 2 A G RL+ 4 A (SHIELDED) W–B W–B 13 IR1 20 IR1 3 IR2 I13 8 IR2 (SHIELDED) W–B B R G W (SHIELDED) IJ1 12 IJ1 4 IS1 6 IS1 5 1 IS1 2 A19 ABS SPEED SENSOR REAR RH B W (SHIELDED) G (SHIELDED) R 19 1 2 A20 ABS SPEED SENSOR REAR LH EA 215 ABS (ANTI–LOCK BRAKE SYSTEM) (TMM MADE) : PARTS LOCATION CODE A4 A5 SEE PAGE CODE A 28 (1MZ–FE), 30 (5S–FE) C9 B 28 (1MZ–FE), 30 (5S–FE) C10 SEE PAGE A 32 B CODE SEE PAGE J3 33 32 N2 A 33 A8 28 (1MZ–FE), 30 (5S–FE) D1 28 (1MZ–FE), 30 (5S–FE) N3 B 33 A9 28 (1MZ–FE), 30 (5S–FE) D3 32 A19 34 (S/D), 35 (C/P), 36 (W/G) F18 28 (1MZ–FE), 30 (5S–FE) A20 34 (S/D), 35 (C/P), 36 (W/G) J1 33 S10 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1A 1B 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 24 COWL WIRE AND J/B NO NO. 3 (BEHIND COMBINATION METER) 1M 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE EC1 IJ1 IP1 IP3 IR1 IR2 IS1 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ENGINE WIRE AND ENGINE ROOM MAIN WIRE 42 FLOOR NO. 1 WIRE AND COWL WIRE 44 ENGINE WIRE AND COWL WIRE 44 ENGINE ROOM MAIN WIRE AND COWL WIRE 44 FLOOR NO. 2 WIRE AND COWL WIRE : GROUND POINTS CODE EA SEE PAGE 38 (1MZ–FE) 40 (5S–FE) GROUND POINTS LOCATION FRONT RIGHT FENDER : SPLICE POINTS CODE I13 I14 216 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS COWL WIRE CODE I21 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS COWL WIRE 217 ABS (ANTI–LOCK BRAKE SYSTEM) (TMM MADE) SYSTEM OUTLINE THIS SYSTEM CONTROLS THE RESPECTIVE BRAKE FLUID PRESSURES ACTING ON THE DISC BRAKE CYLINDERS OF THE RIGHT FRONT WHEEL, LEFT FRONT WHEEL AND REAR WHEELS WHEN THE BRAKES ARE APPLIED IN A PANIC STOP SO THAT THE WHEELS DO NOT LOCK. THIS RESULTS IN IMPROVED DIRECTIONAL STABILITY AND STEERABILITY DURING PANIC BRAKEING. 1. INPUT SIGNALS (1) SPEED SENSOR SIGNAL THE SPEED OF THE WHEELS IS DETECTED AND INPUT TO TERMINALS FL+, FR+, RL+ AND RR+ OF THE ABS ECU. (2) STOP LIGHT SW SIGNAL A SIGNAL IS INPUT TO TERMINAL STP OF THE ABS ECU WHEN BRAKE PEDAL IS OPERATED. 2. SYSTEM OPERATION DURING SUDDEN BRAKEING THE ABS ECU, WHICH HAS SIGNALS INPUT FROM EACH SENSOR, CONTROLS THE CURRENT FLOWING TO THE SOLENOID INSIDE THE ACTUATOR AND LETS THE HYDRAULIC PRESSURE ACTING ON EACH WHEEL CYLINDER ESCAPE TO THE RESERVOIR. THE PUMP INSIDE THE ACTUATOR IS ALSO OPERATING AT THIS TIME AND IT RETURNS THE BRAKE FLUID FROM THE RESERVOIR TO THE MASTER CYLINDER, THUS PREVENTING LOCKING OF THE VEHICLE WHEELS. IF THE ECU JUDGES THAT THE HYDRAULIC PRESSURE ACTING ON THE WHEEL CYLINDER IS INSUFFICIENT, THE CURRENT ACTING ON THE SOLENOID IS CONTROLLED AND THE HYDRAULIC PRESSURE IS INCREASED. HOLDING OF THE HYDRAULIC PRESSURE IS ALSO CONTROLLED BY THE ECU, BY THE SAME METHOD AS ABOVE. BY REPEATED PRESSURE REDUCTION, HOLDING AND INCREASE ARE REPLATED TO MAINTAIN VEHICLE STABILITY AND TO IMPROVE STEERBILITY DURING SUDDEN BRAKING. SERVICE HINTS A 8, A 9 ABS SPEED SENSOR FRONT LH, RH 1–2 : 0.8 K–1.3 KΩ A19, A20 ABS SPEED SENSOR REAR LH, RH 1–2 : 1.1 K–1.5 KΩ A 4(A), A 5(B) ABS ECU (CONNECT THE ECU CONNECTORS) (A)12–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION AND DATA LINK CONNECTOR 1 (CHECK CONNECTOR) TS–EI NOT CONNECTED (A)15–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION AND DATA LINK CONNECTOR 1 (CHECK CONNECTOR) TS–EI NOT CONNECTED (B) 4–GROUND : ALWAYS CONTINUITY (B) 2–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION (A) 9–GROUND : APPROX. 12 VOLTS WITH BRAKE PEDAL DEPRESSED (B) 1–GROUND : ALWAYS APPROX. 12 VOLTS 218 ABS ( ANTI – LOCK BRAKE SYSTEM) (TMM MADE) -Memo 37 ELECTRIC TENSION REDUCER FROM POWER SOURCE SYSTEM (SEE PAGE 64) 15A ECU–IG B–R 7 1A 16 3C 14 3A B–R B–R 5 3D 3 IS1 B–R IJ1 B–R 1 2 2 T2 TENSION REDUCER SOLENOID LH 1 R 1 T3 TENSION REDUCER SOLENOID RH D25 DIODE (FOR TENSION REDUCER) G 1 R–Y 2 2 2 1 1 W–B BL 220 B10 BUCKLE SW RH W–B B 7, B 8 BUCKLE SW LH * 1 W/ POWER SEAT * 2 W/O POWER SEAT SERVICE HINTS B 7, B 8 BUCKLE SW LH 1–2 : CLOSED WITH DRIVER’S LAP BELT IN USE B10 BUCKLE SW RH 1–2 : CLOSED WITH PASSENGER’S LAP BELT IN USE T 2, T 3 TENSION REDUCER SOLENOID LH, RH 2–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE CODE SEE PAGE B7 32 B10 32 T2 35 B8 32 D25 32 T3 35 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1A 3A 3C SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 24 COWL WIRE AND J/B NO NO. 3 (BEHIND COMBINATION METER) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) IJ1 42 FLOOR NO. 1 WIRE AND COWL WIRE IS1 44 FLOOR NO. 2 WIRE AND COWL WIRE : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION 46 (S/D) BL 48 (C/P) UNDER THE LEFT QUARTER PILLAR 50 (W/G) (* 1) B7 (* 2) B 8 2 1 1 B10 D25 BLACK 1 2 1 2 T2 T3 2 1 2 1 2 X X 221 AUTO ANTENNA (S/D, C/P) * 1 : 6 SPEAKER * 2 : 4 SPEAKER FROM POWER SOURCE SYSTEM (SEE PAGE 64) 20A DOME 15A CIG/RADIO 1 1L 9 1L S8 STEREO COMPONENT AMPLIFIER 1 1C L–R B–R R 2 2G 15A ECU–IG ACC 12 1K 9 II2 9 II2 W L–R R 13 R2 RADIO AND PLAYER (* 1) B II2 B–R 3 J3 JUNCTION CONNECTOR B 8 R B 3 A J3 JUNCTION CONNECTOR A 1 IU1 RADIO SW B–R 8 R 1 OFF GR L–R IM2 ON PLAYER SW 2 IU1 (* 1) P–L (* 1) B–R L–R B–R R 9 IM2 R3 RADIO AND PLAYER (* 2) GR 3 B–R 8 RADIO SW OFF (* 2) P–L (* 2) IU1 B–R L–R B–R P–L 6 4 3 1 R–G B R–W W–B 1 4 5 7 8 6 R 5 Y 10 IU1 2 2 A21 AUTO ANTENNA MOTOR AND CONTROL RELAY 222 IU1 L–Y 9 L M B W–B 3 W–B 3 9 ON PLAYER SW BM SERVICE HINTS A21 AUTO ANTENNA MOTOR AND RELAY 9–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 5–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ACC OR ON POSITION 7–GROUND : ALWAYS APPROX. 12 VOLTS 8–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ACC OR ON POSITION AND RADIO SW ON 3–GROUND : CONTINUITY (UPPER LIMIT SW ON) UNLESS ANTENNA AT UP STOP 2–GROUND : CONTINUITY (DOWN LIMIT SW ON) UNLESS ANTENNA AT DOWN STOP 4–3 : CLOSED WITH IGNITION SW AT ACC OR ON POSITION AND RADIO SW ON AND PLAYER SW OFF UNTIL ANTENNA AT UPPERMOST POSITION 1–2 : CLOSED WITH IGNITION SW AT ACC OR ON POSITION AND RADIO SW OFF AND PLAYER SW OFF UNTIL ANTENNA AT LOWERMOST POSITION 1–2: CLOSED WITH IGNITION SW OFF UNTIL ANTENNA AT LOWERMOST POSITION : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE A21 34 (S/D), 35 (C/P) R2 33 J3 33 R3 33 CODE S8 SEE PAGE 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1C 1K 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 1L 2G : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE IM2 42 INSTRUMENT PANEL WIRE AND CONSOLE BOX WIRE IU1 44 FLOOR NO. 2 WIRE AND INSTRUMENT PANEL WIRE : GROUND POINTS CODE BM SEE PAGE 46 (S/D) GROUND POINTS LOCATION UNDER THE LEFT QUARTER PILLAR 48 (C/P) A21 1 J3 2 A A B 3 4 5 6 R2 R3 B A A B B B B (HINT : SEE PAGE 7) BLUE 3 1 8 3 8 9 X S8 X X 9 223 AUTO ANTENNA (W/G) * 1 : 8 SPEAKER * 2 : 6 SPEAKER FROM POWER SOURCE SYSTEM (SEE PAGE 64) 20A DOME 15A ECU–IG 1 1L 9 1L S8 STEREO COMPONENT AMPLIFIER 1 1C L–R B–R R 2 2G 15A CIG/RADIO ACC 6 1H 9 II2 9 II2 W L–R 13 R2 RADIO AND PLAYER (* 1) B B 3 B 8 B–R IM2 R 1 IG1 RADIO SW 8 OFF GR L–R R B–R J3 JUNCTION CONNECTOR ON PLAYER SW 1 2 IG1 (* 1) P–L (* 1) B–R L–R B–R 9 IM2 R3 RADIO AND PLAYER (* 2) GR 3 B–R 8 RADIO SW OFF (* 2) P–L (* 2) B–R L–R B–R P–L 5 6 4 3 1 R–G B R–W W–B 1 4 5 7 8 6 R 2 Y 10 IG1 L–Y A21 AUTO ANTENNA MOTOR AND RELAY 9 IG1 9 ON PLAYER SW W–B C J5 JUNCTION CONNECTOR C L M B 3 W–B 2 BL 224 SERVICE HINTS A21 AUTO ANTENNA MOTOR AND RELAY 9–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION 5–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ACC OR ON POSITION 7–GROUND : ALWAYS APPROX. 12 VOLTS 8–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ACC OR ON POSITION AND RADIO SW ON 3–GROUND : CONTINUITY (UPPER LIMIT SW ON) UNLESS ANTENNA AT UP STOP 2–GROUND : CONTINUITY (DOWN LIMIT SW ON) UNLESS ANTENNA AT DOWN STOP 4–3 : CLOSED WITH IGNITION SW AT ACC OR ON POSITION AND RADIO SW ON AND PLAYER SW OFF UNTIL ANTENNA AT UPPERMOST POSITION 1–2 : CLOSED WITH IGNITION SW AT ACC OR ON POSITION AND RADIO SW OFF AND PLAYER SW OFF UNTIL ANTENNA AT LOWERMOST POSITION 1–2 : CLOSED WITH IGNITION SW OFF UNTIL ANTENNA AT LOWERMOST POSITION : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE CODE SEE PAGE A21 36 (W/G) J5 36 (W/G) R3 33 J3 33 R2 33 S8 33 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1C 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 1H 20 FLOOR NO. 1 WIRE J/B NO. 1 (INSTRUMENT PANEL LEFT) 1L 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 2G 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE IM2 42 INSTRUMENT PANEL WIRE AND CONSOLE BOX WIRE IG1 42 FLOOR NO. 1 WIRE AND INSTRUMENT PANEL WIRE : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION 46 (S/D) 48 (C/P) BL UNDER THE LEFT QUARTER PILLAR 50 (W/G) A21 1 J3 2 J5 B 3 4 5 6 R2 B B B B B C C C C C C C C 1 3 C C (HINT : SEE PAGE 7) 8 X (HINT : SEE PAGE 7) R3 BLUE 3 S8 X X 9 8 9 225 RADIO AND PLAYER (S/D, C/P 6 SPEAKER) FROM POWER SOURCE SYSTEM (SEE PAGE 64) TO AUTO ANTENNA MOTOR AND RELAY 15A CIG/RADIO B–R 20A DOME 2 2G 9 1L B–R R 9 IU1 L–R 1 1C 8 IM2 B–R 12 1K R TO AUTO ANTENNA MOTOR AND RELAY R2 RADIO AND PLAYER 8 ANT II2 ACC 3 B MUTE FR 5 FL 7 RR 6 RL 15 14 BR B L G Y 3 A 9 A B AMP S8 R 1 A ACC 12 A 4 A 6 A 5 A 14 A 13 A (SHIELDED) I15 7 A 11 A W B R (SHIELDED) R R 10 B BEEP 13 I15 GR 3 IM2 L–Y GR B 4 IM2 SGND 12 A , S9 ACC 10 A GND SGND BEEP MUTE FR FL RR RL B STEREO COMPONENT AMPLIFIER LG L 1 2 F10 FRONT DOOR SPEAKER LH IH 226 2 R12 REAR SPEAKER LH 1 L 9 LG 2 R13 REAR SPEAKER RH IT2 IT2 1 2 F13 FRONT TWEETER (SPEAKER) RH 1 2 F11 FRONT DOOR SPEAKER RH L V F12 FRONT TWEETER (SPEAKER) LH 1 4 LG B V P P BR 2 5 B L 17 IG1 W 7 IG1 R 18 IG1 Y 8 IG1 P 13 IH1 1 B LG W 5 IM2 W R 1 IM2 R Y 3 IM1 Y 1 IM1 B 6 IM1 1 4 B FR– 2 IM1 IH1 3 B FR+ 6 IM2 8 9 B RR– 2 IM2 7 IM2 8 B RR+ 2 B V 6 B RL– 7 B B RL+ V FL– P FL+ BR E (SHIELDED) 9 IM2 A GND 11 W B B 4 1 BR A AMP P–L L–R 9 R II2 L–Y J3 JUNCTION CONNECTOR 3 SERVICE HINTS S 8(A), S 9(B) STEREO COMPONENT AMPLIFIER (A) 7–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON OR ACC POSITION (B) 7–GROUND : ALWAYS CONTINUITY (B)10–GROUND : ALWAYS APPROX. 12 VOLTS : PARTS LOCATION CODE SEE PAGE F10 28 (1MZ–FE), 30 (5S–FE) CODE SEE PAGE CODE SEE PAGE J3 33 S8 A 33 S9 B 33 F11 34 (S/D), 35 (C/P) R2 33 F12 34 (S/D), 35 (C/P) R12 34 (S/D), 35 (C/P) F13 34 (S/D), 35 (C/P) R13 34 (S/D), 35 (C/P) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1C 1K 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 1L 2G : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) IG1 42 FLOOR NO. 1 WIRE AND INSTRUMENT PANEL WIRE IH1 42 FRONT DOOR LH WIRE AND INSTRUMENT PANEL WIRE II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE 42 INSTRUMENT PANEL WIRE AND CONSOLE BOX WIRE IT2 44 FRONT DOOR RH WIRE AND INSTRUMENT PANEL WIRE IU1 44 FLOOR NO. 2 WIRE AND INSTRUMENT PANEL WIRE IM1 IM2 : GROUND POINTS CODE IH SEE PAGE GROUND POINTS LOCATION 42 INSTRUMENT PANEL BRACE RH : SPLICE POINTS CODE I15 SEE PAGE WIRE HARNESS WITH SPLICE POINTS 44 CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS CONSOLE BOX WIRE F10, F11 BLACK F12, F13 J3 A A B R2 B A A B B B B 1 1 2 (HINT : SEE PAGE 7) 2 S8 A 1 X 3 R12, R13 BLUE 1 8 3 4 X 11 12 13 5 6 7 2 1 14 15 S9 B 4 5 6 7 X 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 227 RADIO AND PLAYER (S/D, C/P 4 SPEAKER) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 20A DOME 15A CIG/RADIO 9 1L R 2 2G L–R 1 1C R 12 1K A B J3 JUNCTION CONNECTOR IU1 BR IH 228 RR– W R 2 R12 REAR SPEAKER LH 1 2 R13 REAR SPEAKER RH FR– 1 B 5 B 4 L R 17 IG1 1 FR+ 3 A 7 IG1 B F10 FRONT DOOR SPEAKER LH RR+ 1 A 18 IG1 V 2 RL– 6 A 8 IG1 V P BR 1 RL+ 2 A 13 IH1 P IH1 A ACC Y FL– 6 B B , R4 RADIO AND PLAYER Y FL+ B R3 IT2 9 IT2 L ANP 2 B 8 3 B B E 7 B 4 B LG 9 B GR P–L 8 B B L–Y B–R A ANT II2 LG 10 9 W 9 IU1 II2 L–R P–L B–R 3 R TO AUTO ANTENNA MOTOR AND RELAY 1 2 F11 FRONT DOOR SPEAKER RH SERVICE HINTS R 3(B) RADIO AND PLAYER (B) 3–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON OR ACC POSITION (B) 4–GROUND : ALWAYS APPROX. 12 VOLTS (B) 7–GROUND : ALWAYS CONTINUITY : PARTS LOCATION CODE SEE PAGE CODE F10 28 (1MZ–FE), 30 (5S–FE) R3 F11 34 (S/D), 35 (C/P) R4 J3 33 SEE PAGE B 33 A 33 R12 CODE R13 SEE PAGE 34 (S/D), 35 (C/P) 34 (S/D), 35 (C/P) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1C 1K 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 1L 2G : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) IG1 42 FLOOR NO. 1 WIRE AND INSTRUMENT PANEL WIRE IH1 42 FRONT DOOR LH WIRE AND INSTRUMENT PANEL WIRE II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE IT2 44 FRONT DOOR RH WIRE AND INSTRUMENT PANEL WIRE IU1 44 FLOOR NO. 2 WIRE AND INSTRUMENT PANEL WIRE : GROUND POINTS CODE IH SEE PAGE 42 GROUND POINTS LOCATION INSTRUMENT PANEL BRACE RH F10, F11 BLACK J3 A A B R3 B B 1 2 5 6 BLUE 3 4 R4 A 1 BLUE R12, R13 2 A A B B B B 1 2 7 8 9 3 X 6 2 1 (HINT : SEE PAGE 7) 229 RADIO AND PLAYER (W/G 8 SPEAKER) FROM POWER SOURCE SYSTEM (SEE PAGE 64) TO AUTO ANTENNA MOTOR AND RELAY L–R 1 1C B–R B–R 8 IM2 R2 RADIO AND PLAYER 8 R 12 1K 9 IG1 B–R 9 1L R 2 2G 15A CIG/RADIO TO AUTO ANTENNA MOTOR AND RELAY 20A DOME ANT II2 B ACC 4 GND 3 11 B 5 FR FL 7 RR 6 15 RL 14 B L G Y 12 A 4 A 6 A 5 A 14 A 13 A (SHIELDED) 3 A AMP S8 BR 1 A ACC R 7 A 11 A W B R (SHIELDED) R I15 R 10 B MUTE I15 GR 3 IM2 L–Y GR B 4 IM2 BEEP 13 A ,S9 9 A B 10 A ACC GND SGND BEEP MUTE FR FL RR RL B STEREO COMPONENT AMPLIFIER RL+ 7 IM2 8 IH1 2 IM1 6 IM1 Y Y 9 B 8 IG1 18 IG1 13 IH1 D Y 6 IM2 RL– 8 B B V 2 IM2 V 6 B B 2 B B 7 B P FL– P FL+ BR E J5 JUNCTION CONNECTOR E D E B Y 4 Bc3 Y 1 Bc3 4 Bd1 1 Bd1 1 IH 230 2 F11 FRONT DOOR SPEAKER LH 1 2 R14 REAR TWEETER (SPEAKER) LH Y B V B F13 FRONT TWEETER (SPEAKER) LH P Y 5 Bc3 10 Bc3 B 2 E Y 1 B V P BR D 1 2 R12 REAR SPEAKER LH (SHIELDED) 9 IM2 A SGND 12 W B 1 BR A AMP P–L L–R 9 R II2 L–Y J3 JUNCTION CONNECTOR 3 S8 A ,S9 B STEREO COMPONENT AMPLIFIER RR– R 17 IG1 1 IM2 5 IM2 B L J5 JUNCTION CONNECTOR LG W R IG1 A 5 B LG W 3 IM1 FR– 1 B W R 1 IM1 7 FR+ 4 B L RR+ 3 B B A 4 IT2 9 IT2 L LG W 1 Bb1 1 2 F14 FRONT TWEETER (SPEAKER) RH W 2 Bd1 2 Bb1 R W L LG R 5 Bd1 R 3 Bc3 W 9 Bc3 R W B R A 1 2 R13 REAR SPEAKER RH 1 2 R15 REAR TWEETER (SPEAKER) RH 1 2 F12 FRONT DOOR SPEAKER RH 231 RADIO AND PLAYER (W/G 8 SPEAKER) SERVICE HINTS S 8(A), S 9(B) STEREO COMPONENT AMPLIFIER (A) 7–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON OR ACC POSITION (B) 7–GROUND : ALWAYS CONTINUITY (B)10–GROUND : ALWAYS APPROX. 12 VOLTS : PARTS LOCATION CODE SEE PAGE F11 36 (W/G) F12 F13 CODE SEE PAGE CODE SEE PAGE J5 36 R15 36 (W/G) 36 (W/G) R2 33 S8 A 33 36 (W/G) R12 36 (W/G) S9 B 33 F14 36 (W/G) R13 36 (W/G) J3 33 R14 36 (W/G) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1C 1K 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 1L 2G : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) IG1 42 FLOOR NO. 1 WIRE AND INSTRUMENT PANEL WIRE IH1 42 FRONT DOOR LH WIRE AND INSTRUMENT PANEL WIRE II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE 42 INSTRUMENT PANEL WIRE AND CONSOLE BOX WIRE IM1 IM2 IT2 44 FRONT DOOR RH WIRE AND INSTRUMENT PANEL WIRE Bb1 50 (W/G) LUGGAGE ROOM NO. 1 WIRE AND FLOOR NO. 1 WIRE Bc3 50 (W/G) BACK DOOR NO. 1 WIRE AND FLOOR NO. 1 WIRE Bd1 50 (W/G) BACK DOOR NO. 1 WIRE AND BACK DOOR NO. 2 WIRE : GROUND POINTS CODE IH SEE PAGE 42 GROUND POINTS LOCATION INSTRUMENT PANEL BRACE RH : SPLICE POINTS CODE I15 232 SEE PAGE 44 WIRE HARNESS WITH SPLICE POINTS CONSOLE BOX WIRE CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS RADIO AND PLAYER (W/G 6 SPEAKER) SERVICE HINTS R 3(B) RADIO AND PLAYER (B) 3–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON OR ACC POSITION (B) 4–GROUND : ALWAYS APPROX. 12 VOLTS (B) 7–GROUND : ALWAYS CONTINUITY : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE F11 36 (W/G) R3 F12 36 (W/G) R4 J3 33 R12 36 (W/G) J5 36 R13 36 (W/G) CODE SEE PAGE B 33 R14 36 (W/G) A 33 R15 36 (W/G) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1C 1K 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 1L 2G : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) IG1 42 FLOOR NO. 1 WIRE AND INSTRUMENT PANEL WIRE IH1 42 FRONT DOOR LH WIRE AND INSTRUMENT PANEL WIRE II2 42 INSTRUMENT PANEL WIRE AND COWL WIRE IT2 44 FRONT DOOR RH WIRE AND INSTRUMENT PANEL WIRE IU1 44 FLOOR NO. 2 WIRE AND INSTRUMENT PANEL WIRE Bb1 50 (W/G) LUGGAGE ROOM NO. 1 WIRE AND FLOOR NO. 1 WIRE Bc3 50 (W/G) BACK DOOR NO. 1 WIRE AND FLOOR NO. 1 WIRE Bd1 50 (W/G) BACK DOOR NO. 1 WIRE AND BACK DOOR NO. 2 WIRE : GROUND POINTS CODE IH SEE PAGE 42 GROUND POINTS LOCATION INSTRUMENT PANEL BRACE RH 233 RADIO AND PLAYER (W/G 6 SPEAKER) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 20A DOME 9 1L R 2 2G 15A CIG/RADIO L–R 1 1C R 12 1K A B J3 JUNCTION CONNECTOR 9 IU1 10 IU1 B B–R P–L 4 B GR B L–Y A P–L II2 B–R 9 L–R II2 R 3 TO AUTO ANTENNA MOTOR AND RELAY 3 B 8 B 9 B ACC R3 ANT B , R4 ANP A RADIO AND PLAYER RL+ RL– 8 IG1 18 IG1 D J5 JUNCTION CONNECTOR Y Y 6 A B 2 A B V FL– 6 B P FL+ 2 B BR E 7 B E D E 13 IH1 B Y 1 Bc3 10 Bc3 4 Bc3 B Y 4 Bd1 1 Bd1 B B 1 2 BR F11 FRONT DOOR SPEAKER LH IH 234 1 2 R14 REAR TWEETER (SPEAKER) LH Y Y 5 Bc3 Y E B D V P 8 IH1 1 2 R12 REAR SPEAKER LH R3 B ,R4 A RADIO AND PLAYER RR+ RR– A FR– 1 B 5 B J5 JUNCTION CONNECTOR IG1 L W 17 LG R IG1 R 7 FR+ 3 A W 1 A B B A 4 W 1 Bb1 2 Bb1 L IT2 W R 2 Bd1 9 R W 5 Bd1 IT2 LG R 3 Bc3 W 9 Bc3 R W B R A 1 2 R13 REAR SPEAKER RH 1 2 R15 REAR TWEETER (SPEAKER) RH 1 2 F12 FRONT DOOR SPEAKER RH 235 COMBINATION METER FROM POWER SOURCE SYSTEM (SEE PAGE 64) 6 1D 6 1B R–L R–L 10A GAUGE FROM ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU)(A/T) FROM ENGINE CONTROL MODULE (ENGINE ECU)(M/T) FROM CRUISE CONTROL ECU C 2 J2 JUNCTION CONNECTOR IP3 V–Y R–L B , C10 C 7 C 5 A 12 A 4 C 12 3C Y–G IP3 14 IP3 (* 6) G–B TAC (* 7) B A C14 COOLING FAN ECU (* 6) A ED 236 LG 2 3 6 I2 IGNITER J7 JUNCTION CONNECTOR BR BR 4 F15 FUEL SENDER B IP3 R–L V5 VEHICLE SPEED SENSOR (SPEED SENSOR) 5 IP3 1 1 R–L 16 (* 6) 3 (* 7) 2 B BR 1 IP1 BR Y–L 12 3D 8 P W2 WATER TEMP. SENDER 13 3D 3 BX1 Y–R 2 BX1 BR Y–L Y–R 1 1 BX1 Y–B R–W 13 3C 11 Y–B IJ1 O1 OIL PRESSURE SW 18 TO INTEGRATION RELAY IJ1 12 1D B 11 IP3 I9 BR IJ1 10 B G–B G–B 6 5 7 B 13 1D BR Y–L Y–R I9 BR OIL ABS SPEED 11 B G 8 C Y–G 6 A SEAT BELT 4 A TACHO WATER TEMP. 7 A BR 8 A BR FUEL FUEL A ,C9 COMBINATION METER TO ABS ECU C8 6 B B R–L C I18 R–L TO BACK–UP LIGHT SW (M/T) TO PARK/NEUTRAL POSITION SW (NEUTRAL START SW)(A/T) TO GENERATOR (ALTERNATOR) 5 1M 8 1C 1 8 3D II1 2 8 3C I6 1 D E B B II1 (CANADA) E (USA) 1 C W–B D HIGH BEAM R–Y (CANADA) R–G (USA) FROM ” HEAD (UPR–RH)” FUSE FROM ” HEAD RH” FUSE W–R 2 C R–B SRS 9 B J3 JUNCTION CONNECTOR 8 B B–Y 10 A J2 JUNCTION CONNECTOR B–O 7. 5A IGN TO DIMMER SW [COMB. SW] 10 3A CHARGE (* 1) 3 1D TO CENTER AIRBAG SENSOR ASSEMBLY R–W Y (* 1) 10A STARTER B–Y 8 O/D OFF TO LIGHT FAILURE SENSOR B–W 1 TO GENERATOR (ALTERNATOR) PKB Y R–Y G–O A (* 2) BRK G–O 12 B G–O G–O 18 D4 DAYTIME RUNNING LIGHT RELAY (MAIN) (CANADA) G–O A (1MZ–FE A/T) Y–G 3 B TO O/D MAIN SW 4 REAR LIGHT B–W B , C10 C 15 B P2 PARKING BRAKE SW A (USA) BULB CHECK BRAKE 20 3B FROM A/T INDICATOR LIGHT IE R–Y R–Y 2 3C R–W 2 R–W R–Y (* 3) COMBINATION METER (EX. 1MZ–FE A/T) F R–W F P3 PARKING BRAKE SW 19 3D B2 BRAKE FLUID LEVEL SW 1 J2 JUNCTION CONNECTOR 19 3B J2 JUNCTION CONNECTOR 18 3D W–B (* 5) 3 C W–B 8 3B G–R (* 4) O CRUISE A ,C9 W–B (* 5) 9 A G–R (* 4) O G–L C8 TO ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU)(A/T) TO ENGINE CONTROL MODULE (ENGINE ECU)(M/T) TO CRUISE CONTROL ECU G–L * 1 : W/O A/T INDICATOR LIGHT * 2 : W/ A/T INDICATOR LIGHT * 3 : MALFUNCTION INDICATOR LAMP (CHECK ENGINE WARNING LIGHT) *4 *5 *6 *7 : : : : TMC MADE TMM MADE 1MZ–FE 5S–FE FROM POWER SOURCE SYSTEM (SEE PAGE 64) 7. 5A SRS 4 3 1F 13 B 14 B IF 237 W–B TO RHEOSTAT R–Y C8 238 A ,C9 B , C10 C 13 A 11 A R 2 A 1 A 3 A 2 1D 6 3D 8 1L 18 3C 11 1C 1 1M IG OPEN DOOR G G–B L–R R FROM HAZARD SW (TL) FROM HAZARD SW (TR) I13 TURN LH 16 B L–R G–Y 4 3C 6 II1 (* 1) L–R 5 3D TURN RH 11 1D (* 1) G 10 1D POWER METER ILLUMINATION 20 3D R TO ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) FROM ELECTRONIC CONTROLLED TRANSMISSION PATTERN SELECT SW 14 1D W–B B L–R G 15A TAIL TO DOOR COURTESY SW W–B B G COMBINATION METER * 1 : W/O A/T INDICATOR FROM POWER SOURCE SYSTEM (SEE PAGE 64) 20A DOME 2 2G 1 1C 5 1C 9 3D 14 3C 16 3A 4 B COMBINATION METER 5 B SERVICE HINTS B 2 BRAKE FLUID LEVEL SW 1–2 : CLOSED WITH FLOAT DOWN C 8(A), C 9(B), C10(C) COMBINATION METER (A)2, (B)6, (B)9–GROUND : APPROX. 12 VOLTS WITH IGNITION SW AT ON POSITION (A)3, (B)14, (C)8–GROUND : ALWAYS CONTINUITY F15 FUEL SENDER 2–3 : APPROX. 3
WITH FUEL FULL APPROX. 110.0
WITH FUEL EMPTY O 1 OIL PRESSURE SW 1–GROUND : CLOSED WITH OIL PRESSURE BELOW 0.2 KG/CM2 (2.84 PSI, 19.61 KPA) P 2 PARKING BRAKE SW (1MZ–FE A/T) 1–GROUND : CLOSED WITH PARKING BRAKE PEDAL DEPRESSED P 3 PARKING BRAKE SW (EX. 1MZ–FE A/T) 1–GROUND : CLOSED WITH PARKING BRAKE LEVER PULLED UP : PARTS LOCATION CODE SEE PAGE B2 CODE SEE PAGE CODE SEE PAGE 28 (1MZ–FE), 30 (5S–FE) D4 32 P2 33 C8 A 32 F15 34 (S/D), 35 (C/P), 36 (W/G) P3 33 C9 B 32 I2 28 (1MZ–FE), 30 (5S–FE) V5 28 (1MZ–FE), 30 (5S–FE) C10 C 32 J2 33 W2 28 (1MZ–FE), 30 (5S–FE) 32 O1 28 (1MZ–FE), 30 (5S–FE) C14 : RELAY BLOCKS CODE 1 SEE PAGE 25 RELAY BLOCKS (RELAY BLOCK LOCATION) R/B NO. 1 (LEFT KICK PANEL) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1B 1C 1D 1F 20 COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO NO. 3 (BEHIND COMBINATION METER) 1L 1M 2G 3A 3B 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) II1 42 COWL WIRE AND INSTRUMENT PANEL WIRE IJ1 42 FLOOR NO. 1 WIRE AND COWL WIRE 44 ENGINE WIRE AND COWL WIRE IP1 IP3 46 (S/D) BX1 48 (C/P) FUEL GAUGE WIRE AND FLOOR NO. 1 WIRE 50 (W/G) : GROUND POINTS CODE ED SEE PAGE 38 (1MZ–FE) 40 (5S–FE) GROUND POINTS LOCATION INTAKE MANIFOLD LH IE IF IG 42 LEFT KICK PANEL 42 INSTRUMENT PANEL BRACE LH : SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS I6 44 INSTRUMENT PANEL WIRE I13 44 COWL WIRE I9 44 COWL WIRE I18 44 ENGINE WIRE 239 COMBINATION METER 240 RADIATOR FAN AND CONDENSER FAN (5S–FE) : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE A1 30 E5 30 (5S–FE) A2 30 (5S–FE) R1 30 (5S–FE) CODE SEE PAGE : RELAY BLOCKS CODE 5 SEE PAGE 26 RELAY BLOCKS (RELAY BLOCK LOCATION) R/B NO. 5 (ENGINE COMPARTMENT LEFT) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1A 2B 2E 3A 3C SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 22 ENGINE ROOM MAIN WIRE AND J/B NO NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO NO. 3 (BEHIND COMBINATION METER) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE EA1 SEE PAGE 40 (5S–FE) JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ENGINE ROOM MAIN WIRE AND ENGINE ROOM NO. 3 WIRE : GROUND POINTS CODE EB SEE PAGE 40 (5S–FE) GROUND POINTS LOCATION FRONT LEFT FENDER : SPLICE POINTS CODE E5 SEE PAGE 40 (5S–FE) WIRE HARNESS WITH SPLICE POINTS CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS ENGINE ROOM MAIN WIRE 241 RADIATOR FAN AND CONDENSER FAN (5S–FE) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 15A ECU–IG 30A CDS FAN 30A RDI FAN 4 2B B–R 7 1A W 16 3C 15 3A B–O 2 M 6 2G 1 5 2E 1 L 3 2 4 8 2E 3 2B R RADIATOR FAN RELAY 5 1 2B B L A2 A/C SINGLE PRESSURE SW B–R L–B 5 6 2E 2 2 3 4 RADIATOR FAN RELAY NO. 2 1 B–R W–R B–W B–R FROM A/C MAGNETIC CLUTCH RELAY 5 2 R1 RADIATOR FAN MOTOR 5 M 1 RADIATOR FAN RELAY NO. 3 1 2 3 E5 WATER TEMP. SW (FOR COOLING FAN) 5 W–B B–R W–B 5 1 EA1 2 5 B 5 W–B E5 W–B W–B 5 5 5 3 1 A1 A/C CONDENSER FAN MOTOR EB 242 W–B W–B 2 EA1 EB SYSTEM OUTLINE FAN MOTOR OPERATION WITH THE IGNITION SW IS TURNED ON, CURRENT FLOWS FROM ECU–IG FUSE TO RADIATOR FAN RELAY NO. 1 (COIL SIDE) AND RADIATOR FAN RELAY NO. 2 (COIL SIDE) → TERMINAL 2 OF THE A/C SINGLE PRESSURE SW → TERMINAL 3 → TERMINAL 2 OF THE WATER TEMP. SW → TERMINAL 1 → GROUND, AND RADIATOR FAN RELAY NO. 1 AND NO. 2 ARE TURNED ON. ∗ RADIATOR FAN MOTOR OPERATION WHEN THE IGNITION SW IS TURNED ON, RADIATOR FAN RELAY NO. 1 IS TURNED ON. IF AT THIS TIME THE ENGINE COOLANT TEMPERATURE IS APPROX. 90°C (194°F) OR HIGHER, THE WATER TEMP. SW IS TURNED OFF, RADIATOR FAN RELAY NO. 1 IS TURNED OFF. AS A RESULT, CURRENT FROM THE RDI FAN FUSE TO RADIATOR FAN RELAY NO. 1 (POINT SIDE) → TERMINAL 2 OF THE RADIATOR FAN MOTOR → TERMINAL 1 → GROUND, THUS ACTIVATING THE ROTATION OF THE RADIATOR FAN MOTOR. ∗ LOW SPEED OPERATION WHEN THE IGNITION SW IS TURNED ON AND THE A/C ACTIVATED, RADIATOR FAN RELAY NO. 1 AND RADIATOR FAN RELAY NO. 2 ARE TURNED ON, CURRENT FLOWS FROM A/C MAGNETIC CLUTCH RELAY (POINT SIDE) TO RADIATOR FAN RELAY NO. 3 (COIL SIDE) → GROUND, AND RADIATOR FAN RELAY NO. 3 IS TURNED ON. AS A RESULT, CURRENT FLOWS FROM CDS FAN FUSE TO TERMINAL 2 OF THE A/C CONDENSER FAN MOTOR → TERMINAL 1 → RADIAOTR FAN RELAY NO. 2 (POINT SIDE) → RADIATOR FAN RELAY NO. 3 (POINT SIDE) → TERMINAL 2 OF THE RADIATOR FAN MOTOR → TERMINAL 1 → GROUND, FLOWING TO EACH FAN MOTOR IN SERIES, CAUSING THE FAN TO AT LOW SPEED. ∗ HIGH SPEED OPERATION OF THE FAN MOTOR DUARING A/C OPERATION WHEN THE A/C OPERATION, THE REFRIGERRANT PRESSURE BECOME HIGHER THAN OR DINARY LEVEL (APPROX. 15.58 KG/CM2 (221.2 PSI, 1527 KPA)) THE A/C SINGLE PRESSURE SW IS TURNED OFF. AS A RESULT, RADIATOR FAN RELAY NO. 1 AND RADIATOR FAN RELAY NO. 2 ARE TURNED OFF, AND CURRENT FLOWS FROM RDI FUSE TO RADIATOR FAN RELAY NO. 1 (POINT SIDE) → TERMINAL 2 OF THE RADIATOR FAN MOTOR → TERMINAL 1 → GROUND, AND CURRENT FLOWS FROM CDS FAN FUSE TO TERMINAL 2 OF THE A/C CONDENSER FAN MOTOR → TERMINAL 1 → RADIATOR FAN RELAY NO. 2 (POINT SIDE) → GROUND, AND TO EACH FAN MOTOR IN PARALLEL, THUS CAUSING THE FAN MOTORS OPERATE HIGH SPEED. NOTE THAT, BECAUSE THE CURRENT FLOWS IN THE SAME MENNER EVEN IF THE ENGINE COOLANT TEMPERATURE IS APPROX. 90°C (194°F) OR HIGHER, THE FAN MOTOR OPERATE AT HIGH SPEED. SERVICE HINTS A 2 A/C SINGLE PRESSURE SW 2–3 : OPEN ABOVE APPROX. 15.58 KG/CM2 (221.2 PSI, 1527 KPA) CLOSE BELOW APPROX. 15.56 KG/CM2 (178.4 PSI, 1231 KPA) A1 1 BLACK A2 BLACK 2 E5 1 2 R1 GRAY 2 3 1 2 243 ELECTRONICALLY CONTROLLED HYDRAULIC COOLING FAN (1MZ–FE) FROM POWER SOURCE SYSTEM (SEE PAGE 64) 15A ECU–IG B–R 7 1A TO COMBINATION METER FROM THROTTLE POSITION SENSOR 16 3C FROM ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) L L I18 IP2 L W–R 7 B B–R 15 3A 1 6 IGB TAC 5 IDL SOL– 2 3 10 TH– TH+ HP 9 8 Y–L L–R BR L–W SOL+ L–Y E 4 Y C14 COOLING FAN ECU I18 L–W L–R 1 1 L–W 8 EC1 2 6 3 2 OPT S1 SOLENOID VALVE (FOR HYDRAULIC MOTOR) D1 DATA LINK CONNECTOR 1 (CHECK CONNECTOR) A2 A/C SINGLE PRESSURE SW 2 BR W–B E5 ENGINE COOLANT TEMP. SENSOR (WATER TEMP. SENSOR) (FOR COOLING FAN) EC 244 EB SYSTEM OUTLINE THE COOLING FAN ECU RECEIVES VARIOUS SIGNAL, I.E., THE ENGINE RPM SIGNAL FROM THE IGNITER, COOLANT TEMPERATURE SIGNAL FROM THE ENGINE COOLANT TEMP. SENSOR (WATER TEMP. SENSOR), A/C REFRIGERANT PRESSURE SIGNAL FROM A/C SINGLE PRESSURE SW. THE COOLING FAN ECU JUDGES THE ENGINE BASED ON SIGNALS FROM ABOVE MENTION, DRIVES THE SOLENOID VALVE AND CONTROLS THE SPEED OF THE COOLING FAN STEPLESSLY FAIL–SAFE FUNCTION WHEN THE MALFANCTION IS DETECTED BY THE ENGINE COOLANT TEMP. SENSOR (WATER TEMP. SENSOR) OR SOLENOID VALVE, THE FAIL–SAFE FUNCTION OF THE COOLING FAN ECU JUDGES THE SITUATION TO ALLOWS THE COOLING SYSTEM TO CONTINUE OPERATION. SERVICE HINTS A 2 A/C SINGLE PRESSURE SW 2–3 : OPEN ABOVE APPROX. 15.58KG/CM2 (221.2PSI, 1527KPA) CLOSED BELOW APPROX. 12.56 KG/CM2 (178.4PSI, 1231KPA) C14 COOLING FAN ECU 1–GROUND : APPROX. 12 VOLTS WITH THE IGNITION SW ON 9–10 : 2.5 VOLTS AT 20°C (68°F) AND IGNITION SW ON 1.2 VOLTS AT 80°C (176°F) AND IGNITION SW ON 8– 4 : 10–14 VOLTS AT A/C PRESSURE SW ON (OPEN) 0–3 VOLTS AT A/C PRESSURE SW OFF (CLOSE) 4–GROUND : ALWAYS CONTINUITY E 5 ENGINE COOLANT TEMP. SENSOR (WATER TEMP. SENSOR) (FOR COOLING FAN) 1–2 : 1.5K
AT 80°C (176°F) 0.7K
AT 110°C (230°F) : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE A2 28 D1 28 C14 32 E5 30 CODE S1 SEE PAGE 29 : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE 1A 3A 3C JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 24 COWL WIRE AND J/B NO NO. 3 (BEHIND COMBINATION METER) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE SEE PAGE JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) EC1 38 (1MZ–FE) ENGINE WIRE AND ENGINE ROOM MAIN WIRE IP2 44 ENGINE WIRE AND COWL WIRE : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION EB 38 (1MZ–FE) FRONT LEFT FENDER EC 38 (1MZ–FE) INTAKE MANIFOLD RH : SPLICE POINTS CODE SEE PAGE I18 44 A2 WIRE HARNESS WITH SPLICE POINTS CODE SEE PAGE BLACK C14 GRAY 1 2 D1 BLACK E5 BROWN S1 1 3 4 5 6 X 8 9 10 2 WIRE HARNESS WITH SPLICE POINTS ENGINE WIRE 1 3 6 X X X X X 2 2 X X X X 245 AIR CONDITIONING (PUSH CONTROL SW TYPE) FROM POWER SOURCE SYSTEM (SEE PAGE 64) B FROM POWER SOURCE SYSTEM (SEE PAGE 64) 40A HEATER 10A GAUGE 4 4 L R–L 6 1B 4 5 R–L 4 1 R–L I5 HEATER RELAY R–L 2 4 3 4 C 4 R–L I7 C B 4 I7 R–L R–L B4 BLOWER MOTOR B W–B R–L J1 JUNCTION CONNECTOR R–L B I21 C 2 W–B L–W M R–L B–R 1 5 B5 BLOWER RESISTOR IK1 1 W–B 12 2 3 L–O L–B B–W 3 IK1 IK1 4 B–W W–B I13 W–B 1 2 W–B 4 M4 M3 M2 M1 LO OFF I14 7 L–W 5 W–B I13 W–B M5 L–B L–O B6 BLOWER SW W–B I12 B–W I14 HI IK1 W–B IK1 II 246 W–B 2 1 W–B B 6 IG W–B 1 H8 HEATER CONTROL SW W–B B R–L R–B 4 R–W 3 A16 AIR INLET CONTROL SERVO MOTOR FRESH/RECIRC 10A A/C R–L M DEF F/D FOOT B/L FACE F L–Y 4 3 2 M R–L 4 A17 AIR VENT MODE CONTROL SERVO MOTOR R R 4 DEF F/D FOOT B/L R–L R–L 7 IL1 W–B 6 CONTROL CIRCUIT FACE B 5 IL1 5 4 3 2 G–W R L–W 6 11 A/C RECIRC/FRESH IL1 FACE 3 10 2 BI–LEVEL FOOT L–O L–Y 5 L–B R–W 4 2 IL1 L–R R–B 8 1 3 IL1 L Y–G 4 IL1 7 1 R–Y 7 B–Y A L–B W–B 6 IL1 R R–L 9 FOOT/DEF DEF H8 HEATER CONTROL SW W–B W–B 247 248 W–B I2 IGNITER 8 TACH 4 G 2 8 9 13 14 12 2 4 4 12 1D IP1 6 TAC C14 COOLING FAN ECU IP3 B–W(* 2) B–W R–L L–Y R–L R–L R–W 5 5 3 5 5 7 G I19 L–Y (* 2) B–W R–L B–Y L–Y (* 2) L–B(* 1) TO RADIATOR FAN RELAY NO. 3 W–L(* 2) 4 TO ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU)(A/T) OR ENGINE CONTROL MODULE (ENGINE ECU)(M/T) 1 1B LG–B 10 L–W(* 1) W–L W–R IR1 FROM ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU)(A/T) OR ENGINE CONTROL MODULE (ENGINE ECU)(M/T) 5 B W–R IP3 (* 1) B 9 (* 2) B A11 A/C EVAPORATOR TEMP. SENSOR W–R L–W 1 R–B R–L B W–B 2 R–W AIR CONDITIONING (PUSH CONTROL SW TYPE) E6 * 1 : 1MZ–FE * 2 : 5S–FE R–B 5 1 A/C MAGNETIC CLUTCH RELAY 2 5 B–W (* 1) W–R 4 EC1 1 4 A3 A/C MAGNETIC CLUTCH AND LOCK SENSOR A2 A/C DUAL PRESSURE SW 1 4 IR1 6 A10 A/C AMPLIFIER 1 IR1 SYSTEM OUTLINE 1. AIR INLET CONTROL SERVO MOTOR OPERATION (FOR PUSH SW TYPE) (SWITCHING FROM FRESH TO RECIRC) WITH THE IGNITION SW ON, CURRENT FROM THE GAUGE FUSE FLOWS TO TERMINAL 1 OF THE SERVO MOTOR. WHEN THE RECIRC SW IS TURNED ON, THE CURRENT FLOWS FROM SERVO MOTOR → TERMINAL 3 → TERMINAL 5 OF THE HEATER CONTROL SW → TERMINAL 1 → GROUND, THE MOTOR ROTATES AND THE DAMPER MOVES TO THE RECIRC SIDE. WHEN IT IS IN THE RECIRC POSITION, THE CIRCUIT IS CUT INSIDE THE SERVO MOTOR AND THE DAMPER STOPS IN THAT POSITION. WHEN THE CIRCUIT FOR THE INDICATOR LIGHT, CURRENT FLOWS FROM THE GAUGE FUSE → TERMINAL 12 OF THE HEATER CONTROL SW → INDICATOR LIGHT → TERMINAL 1 → GROUND AND THE INDICATOR LIGHT CONTINUES TO LIGHT UP WHILE THE RECIRC SW IS ON. (SWITCHING FROM RECIRC TO FRESH) WHEN THE IGNITION IS ON AND THE FRESH SW IS TURNED ON, CURRENT FLOWS FROM TERMINAL 2 OF THE SERVO MOTOR → TERMINAL 6 OF THE HEATER CONTROL SW → TERMINAL 1 → GROUND, THE MOTOR ROTATES AND THE DAMPER MOVES TO THE FRESH SIDE. WHEN THE DAMPER IS IN THE FRESH POSITION, THE CIRCUIT IS CUT INSIDE THE SERVO MOTOR AND THE DAMPER STOPS IN THAT POSITION. 2. OPERATION OF AIR VENT MODE CONTROL SERVO MOTOR WHEN THE IGNITION SW ON, CURRENT FLOWS FROM THE GAUGE FUSE TO TERMINAL 12 OF THE HEATER CONTROL SW, TERMINAL 6 OF THE AIR VENT MODE CONTROL SERVO MOTOR. WHEN THE DAMPER IS IN FACE POSITION AND THE BI–LEVEL OF THE HEATER CONTROL SW IS THEN TURNED ON, CURRENT FLOWS FROM TERMINAL 3 OF THE HEATER CONTROL SW → TERMINAL 4 OF THE AIR VENT MODE CONTROL SERVO MOTOR SO THAT A SINGAL THAT THE GROUND CIRCUIT IS ACTIVATED IS INPUT TO TERMINAL “B” OF THE CONTROL CIRCUIT INSIDE THE AIR VENT MODE CONTROL SERVO MOTOR. SIMULTANEOUSLY, A SIGNAL THAT THE GROUND CIRCUIT IS NOT ACTIVATED IS INPUT TO TERMINAL “A” OF THE CONTROL CIRCUIT INSIDE THE SERVO MOTOR. THESE TWO SIGNALS ACTIVATE THE CONTROL CIRCUIT SO THAT CURRENT FROM THE GAUGE FUSE TO THE SERVO MOTOR, CAUSING THE SERVO MOTOR TO OPERATE AND THE DAMPER TO MOVE TO BI–LEVEL POSITION. WHEN THE DAMPER REACHES BI–LEVEL POSITION, A GROUND CUT SIGNAL IS INPUT TO TERMINAL “B” OF THE CONTROL CIRCUIT, THE CONTROL CIRCUIT OPERATES, THE SERVO MOTOR STOPS ROTATING AND THE DAMPER STOPS AT BI–LEVEL. WHEN ANOTHER MODE POSITION IS SWITCHED TO, INPUT OF SIGNALS TO TERMINAL “A” AND TERMINAL “B” OF THE CONTROL CIRCUIT THAT GROUND IS MADE OR GROUND IS NOT MADE (AS EXPLAINED ABOVE) ACTIAVTES THE CONTROL CIRCUIT AND MOVES THE SERVO MOTOR TO THE DESIRED POSITION. 3. AIR CONDITIONING OPERATION WHEN THE IGNITION SW ON, CURRENT FLOWS FROM GAUGE FUSE TO TERMINAL 12 OF THE HEATER CONTROL SW, TERMINAL 6 OF THE AIR VENT MODE CONTROL SERVO MOTOR. WHEN THE BLOWER SW IS ON, CURRENT FLOWS FROM THE GAUGE FUSE → HEATER RELAY (COIL SIDE) → TERMINAL 7 OF THE BLOWER SW → TERMINAL 5 → GROUND, ACTIVATING THE HEATER RELAY. THIS CAUSES CURRENT TO FLOW FROM THE HEATER FUSE TO THE HEATER RELAY (POINT SIDE) → A/C FUSE → TERMINAL 7 OF THE HEATER CONTROL SW (A/C SW). IF THE HEATER CONTROL (A/C SW) IS THEN TURNED ON AT THIS TIME, A SIGNAL IS INPUT TO THE A/C AMPLIFIRE. THIS ACTIVATES THE A/C AMPLIFIER AND A/C MAGNETIC CLUTCH RELAY SO THAT CURRENT FLOWS FROM THE GAUGE FUSE TO THE A/C MAGNETIC CLUTCH RELAY (POINT SIDE) → A/C MAGNETIC CLUTCH, CAUSING THE COMPRESSOR TO OPERATE. THE VSV (FOR A/C IDLE–UP) IS TURNED ON SIMULTANEOUSLY TO PREVENT A DECREASE IN ENGINE SPEED DUE TO A/C OPERATION. SERVICE HINTS HEATER RELAY (4)5– (4)4 : CLOSED WITH THE IGNITION SW ON AND BLOWER SW ON A/C MAGNETIC CLUTCH RELAY (4)5– (4)3 : CLOSED WITH THE IGNITION SW ON AND BLOWER SW ON AND A/C SW ON A 2 A/C DUAL PRESSURE SW 1–4 : OPEN WITH PRESSURE 2.1 KG/CM (30 PSI, 206 KPA) OR ABOVE 27 KG/CM (384 PSI, 2646 KPA) B 5 BLOWER RESISTOR 6–2 : APPROX. 1.12 Ω 2–3 : APPROX. 0.5 Ω 3–1 : APPROX. 0.2 Ω 249 AIR CONDITIONING (PUSH CONTROL SW TYPE) : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE A2 28 (1MZ–FE), 30 (5S–FE) A17 32 CODE SEE PAGE H8 33 A3 28 (1MZ–FE), 30 (5S–FE) B4 32 I2 30 (5S–FE) A10 32 B5 32 J1 33 A11 32 B6 32 A16 32 C14 32 : RELAY BLOCKS CODE SEE PAGE RELAY BLOCKS (RELAY BLOCK LOCATION) 4 25 R/B NO. 4 (RIGHT KICK PANEL) 5 26 R/B NO. 5 (ENGINE COMPARTMENT LEFT) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1B 1D SEE PAGE 20 JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE EC1 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ENGINE WIRE AND ENGINE ROOM MAIN WIRE IK1 42 COWL WIRE AND A/C SUB WIRE IL1 42 COWL WIRE AND SERVO MOTOR SUB WIRE 44 ENGINE WIRE AND COWL WIRE 44 ENGINE ROOM MAIN WIRE AND COWL WIRE IP1 IP3 IR1 : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION IG 42 INSTRUMENT PANEL BRACE LH II 42 RIGHT KICK PANEL : SPLICE POINTS CODE E6 I5 I7 250 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 44 WIRE HARNESS WITH SPLICE POINTS ENGINE ROOM MAIN WIRE COWL WIRE CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS I12 I13 I14 I19 44 COWL WIRE 251 AIR CONDITIONING (LEVER CONTROL SW TYPE) FROM POWER SOURCE SYSTEM (SEE PAGE 64) R–L B 40A HEATER 10A GAUGE 4 R–L 4 5 4 1 2 A17 AIR VENT MODE CONTROL SERVO MOTOR HEATER RELAY 4 3 6 4 IL1 B 4 M FACE L–W B DEF F/D FOOT B/L B I21 W–B R–L I5 R–L 4 I7 J1 JUNCTION CONNECTOR R–L C C R–L R–L 6 1B L 4 R–L 6 CONTROL CIRCUIT B5 BLOWER RESISTOR B DEF F/D FOOT B/L A 2 2 6 1 3 G L Y FACE B4 BLOWER MOTOR B M IK1 4 L–B L–O B–W W–B I12 W–B 4 M1 LO 3 G–W R IL1 IL1 4 5 IL1 IL1 4 5 6 7 8 OFF I14 L–W W–B 1 DEF F/D FOOT B/L FACE W–B B6 BLOWER SW I13 W–B W–B 2 I13 1 252 IL1 W–B 8 M2 W–B 5 HI 3 II 1 W–B IL1 B–W I14 L–B IK1 7 B–W 5 L–W 2 4 L IK1 3 L–R 3 L–B IK1 2 L–O 1 1 B–Y W–B 7 R–Y 1 IG H8 AIR VENT MODE CONTROL SW W–B I19 2 13 8 I2 IGNITER 4 4 1 1B 12 1D IP1 W–B 4 6 FACH TAC C14 COOLING FAN ECU G 2 4 A3 A/C MAGNETIC CLUTCH AND LOCK SENSOR 14 7 A2 A/C DUAL PRESSURE SW B–W (* 2) 5 G W–R (* 2) L–Y R–L 4 L–Y 2 B–W(* 2) TO RADIATOR FAN RELAY NO. 3 B–W R–L 4 B–Y 5 IP3 L–B(* 1) 10A A/C W–L(* 2) R–L IR1 TO ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU)(A/T) OR ENGINE CONTROL MODULE (ENGINE ECU)(M/T) 9 LG–B L–W(* 1) W–R Y–G 4 FROM ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU)(A/T) OR ENGINE CONTROL MODULE (ENGINE ECU)(M/T) W–L W–R 9 B B A11 A/C EVAPORATOR TEMP. SENSOR A12 A/C SW (* 1) B 8 B 10 5 OFF ON 2 L–W 1 R–B R–W R–L (* 2) W–B * 1 : 1MZ–FE * 2 : 5S–FE R–L B E6 1 5 5 A/C MAGNETIC CLUTCH RELAY 5 1 3 2 B–W 5 5 (* 1) W–R 4 EC1 1 1 4 IR1 6 IR1 1 IP3 12 2 A10 A/C AMPLIFIER 1 253 AIR CONDITIONING (LEVER CONTROL SW TYPE) SYSTEM OUTLINE CURRENT ALWAYS FLOWS FROM THE HEATER FUSE TO TERMINAL 5 OF THE HEATER RELAY. WHEN THE IGNITION SW IS TURNED ON, CURRENT FLOWS FROM GAUGE FUSE TO TERMINAL 2 OF THE AIR VENT MODE CONTROL SERVO MOTOR AND A/C MAGNETIC CLUTCH RELAY (COIL SIDE) → TERMINAL 12 OF THE A/C AMPLIFIER, TERMINAL 1 OF THE A/C DUAL PRESSURE SW → TERMINAL 4 → TERMINAL 2 OF THE A/C AMPLIFIER, HEATER RELAY (COIL SIDE) → TERMINAL 3 OF THE BLOWER SW. 1. OPERATION OF AIR VENT MODE CONTROL SERVO MOTOR WHEN THE DAMPER IS IN FACE POSITION AND THE BI–LEVEL OF THE AIR VENT MODE CONTROL SW IS THEN TURNED ON, CURRENT FLOWS FROM TERMINAL 7 OF THE AIR VENT MODE CONTROL SW → TERMINAL 5 OF THE AIR VENT MODE CONTROL SERVO MOTOR SO THAT A SIGNAL THAT THE GROUND CIRCUIT IS ACTIVATED IS INPUT TO TERMINAL “B” OF THE CONTROL CIRCUIT INSIDE THE AIR VENT MODE CONTROL SERVO MOTOR. SIMULTANEOUSLY, A SIGNAL THAT THE GROUND CIRCUIT IS NOT ACTIVATED IS INPUT TO TERMINAL “A” OF THE CONTROL CIRCUIT INSIDE THE SERVO MOTOR. THESE TWO SIGNALS ACTIVATE THE CONTROL CIRCUIT SO THAT CURRENT FROM THE GAUGE FUSE TO THE SERVO MOTOR, CAUSING THE SERVO MOTOR TO OPERATE AND THE DAMPER TO MOVE TO BI–LEVEL POSITION. WHEN THE DAMPER REACHES BI–LEVEL POSITION. A GROUND CUT SIGNAL IS INPUT TO TERMINAL “B” OF THE CONTROL CIRCUIT, THE CONTROL CIRCUIT OPERATES, THE SERVO MOTOR STOPS ROTATING AND THE DAMPER STOPS AT BI–LEVEL. WHEN ANOTHER MODE POSITION IS SWITCHED TO, INPUT OF SIGNALS TO TERMINAL “A” AND TERMINAL “B” OF THE CONTROL CIRCUIT THAT GROUND IS NOT MADE (AS EXPLAINED ABOVE) ACTIVATES THE CONTROL CIRCUIT AND MOVES THE SERVO MOTOR TO THE DESIRED POSITION. 2. AIR CONDITIONING OPERATION WHEN THE BLOWER SW IS ON, CURRENT FLOWS THE GAUGE FUSE → HEATER RELAY (COIL SIDE) → TERMINAL 3 OF THE BLOWER SW → TERMINAL 1 → GROUND, ACTIVATING THE HEATER RELAY. THIS CAUSES CURRENT TO FLOW FROM THE HEATER FUSE TO THE HEATER RELAY (POINT SIDE) → A/C FUSE → TERMINAL 2 OF THE A/C SW. IF THE A/C SW IS THEN TURNED ON AT THIS TIME. A SIGNAL IS INPUT TO THE A/C AMPLIFIER. THIS ACTIVATES THE A/C AMPLIFER AND A/C MAGNETIC CLUTCH RELAY SO THAT CURRENT FLOWS FROM THE GAUGE FUSE TO THE A/C MAGNETIC CLUTCH RELAY (POINT SIDE) → A/C MAGNETIC CLUTCH. CAUSING THE COMPRESSOR TO OPERATE. THE VSV (FOR A/C IDLE–UP) IS TURNED ON SIMULTANEOUSLY TO PREVENT A DECREASE IN ENGINE SPEED DUE TO A/C OPERATION. SERVICE HINTS HEATER RELAY (4)5– (4)4 : CLOSED WITH THE IGNITION SW ON AND BLOWER SW ON A/C MAGNETIC CLUTCH RELAY (5)5– (5)3 : CLOSED WITH THE IGNITION SW ON AND BLOWER SW ON AND A/C SW ON A 2 A/C DUAL PRESSURE SW 1–4 : OPEN WITH PRESSURE 2.1 KG/CM (30 PSI, 206 KPA) OR ABOVE 27 KG/CM (384 PSI, 2646 KPA) B 5 BLOWER RESISTOR 6–1 : APPROX. 3.17 Ω 6–3 : APPROX. 1.38 Ω 2–6 : APPROX. 0.38 Ω : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE A2 28 (1MZ–FE), 30 (5S–FE) A17 32 CODE SEE PAGE H8 33 A3 28 (1MZ–FE), 30 (5S–FE) B4 32 I2 30 (5S–FE) A10 32 B5 32 J1 33 A11 32 B6 32 A12 32 C14 32 : RELAY BLOCKS CODE SEE PAGE RELAY BLOCKS (RELAY BLOCK LOCATION) 4 25 R/B NO. 4 (RIGHT KICK PANEL) 5 26 R/B NO. 5 (ENGINE COMPARTMENT LEFT) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE 1B 1D 254 SEE PAGE 20 JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) COWL WIRE AND J/B NO. NO 1 (INSTRUMENT PANEL LEFT) : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE EC1 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ENGINE WIRE AND ENGINE ROOM MAIN WIRE IK1 42 COWL WIRE AND A/C SUB WIRE IL1 42 COWL WIRE AND SERVO MOTOR SUB WIRE 44 ENGINE WIRE AND COWL WIRE 44 ENGINE ROOM MAIN WIRE AND COWL WIRE IP1 IP3 IR1 : GROUND POINTS CODE SEE PAGE GROUND POINTS LOCATION IG 42 INSTRUMENT PANEL BRACE LH II 42 RIGHT KICK PANEL : SPLICE POINTS CODE E6 I5 I7 SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 44 WIRE HARNESS WITH SPLICE POINTS ENGINE ROOM MAIN WIRE COWL WIRE CODE SEE PAGE WIRE HARNESS WITH SPLICE POINTS I13 I14 44 COWL WIRE I19 255 * 1 : TMC MADE * 2 : TMM MADE * 3 : W/ POWER WINDOW GROUND POINT HIGH BEAM INDICATOR LIGHT [COMB. METER] W–B LIGHT CONTROL SW [COMB. SW] W–B * 4 : W/O POWER WINDOW * 5 : AIR CONDITIONING (PUSH CONTROL SW TYPE) * 6 : AIR CONDITIONING (LEVER CONTROL SW TYPE) 4 IK1 W–B W–B W–B W–B I12 W–B I5 BLOWER SW 7 IL1 W–B I13 W–B W–B W–B KEY INTERLOCK SOLENOID I5 DATA LINK CONNECTOR 3 W–B W–B J1 JUNCTION CONNECTOR W–B I7 W–B I7 W–B REAR WINDOW DEFOGGER SW W–B 6 3C F 6 3D 13 COMBINATION METER W–B W–B 6 W–B CIRCUIT OPENING RELAY DAYTIME RUNNING LIGHT RELAY (MAIN) (CANADA) 14 3B W–B CRUISE CONTROL CLUCH SW 8 1C 18 3C 5 1M W–B 6 IV2 (* 2) W–B (* 2) (* 1) 6 IV1 W–B 6 1I W–B W–B I13 CRUISE CONTROL ECU CRUISE CONTROL SW [COMB. SW] W–B W–B 5 W–B 3B W–B W–B 2 1F B 4 : S/D B30 : W/G B20 : C/P W–B 12 3A W–B W–B VANITY LIGHT RH W–B I7 W–B CENTER AIRBAG SENSOR ASSEMBLY (E2) 3A W–B W–B 1 TURN SIGNAL FLASHER STARTER RELAY F I7 W–B BRAKE FLUID LEVEL SW 1 2F W–B I7 W–B CIGARETTE LIGHTER A/C AMPLIFIER F W–B CLOCK W–B I13 10 W–B 1C DEFOGGER RELAY VANITY LIGHT LH I 7 : *5 I14 : * 6 W–B W–B AIR VENT MODE CONTROL SERVO MOTOR HEATER CONTROL SW (PUSH CONTROL SW TYPE) OR AIR VENT MODE CONTROL SW (LEVER CONTROL SW TYPE) W–B WIPER AND WASHER SW [COMB. SW] BLOWER RESISTOR I5 W–B DIMMER SW [COMB. SW] W–B W–B 11 1C I13 (W/G)(S/D, C/P) NOISE FILTER IE MOON ROOF CONTROL RELAY W–B POWER MAIN RELAY B 5 : S/D B21 : C/P B32 : W/G INTEGRATION RELAY W–B MOON ROOF CONTROL SW AND PERSONAL LIGHT W–B W–B 4 W–B B 4 : S/D B21 : C/P B31 : W/G MOON ROOF LIMIT SW 1G W–B MOON ROOF MOTOR W–B W–B 1 1M 1 1F W–B UNLOCK WARNING SW [IGNITION SW] W–B CENTER AIRBAG SENSOR ASSEMBLY (E1) W–B RADIO AND PLAYER STEREO COMPONENT AMPLIFIER BK : S/D, C/P BP : W/G BR (W/O CD PLAYER) BR 7 IM2 BR (W/ CD PLAYER) IH 256 W–B IG II 4 HEATER RELAY W–B B B W–B 19 W–B W–B DOOR KEY LOCK AND UNLOCK SW RH W–B DOOR LOCK CONTROL SW RH W–B DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT RH IT1 W–B RHEOSTAT B11 : EX. C/P B27 : C/P A/T INDICATOR LIGHT [COMB. METER] W–B B GLOVE BOX LIGHT SW W–B B REMOTE CONTROL MIRROR SW W–B B11 : EX. C/P B27 : C/P W–B B W–B B W–B BACK DOOR LOCK CONTROL SW W–B W–B W–B W–B DOOR KEY CYLINDER LIGHT AND SW DOOR KEY LOCK AND UNLOCK SW LH W–B B1 W–B POWER WINDOW MASTER SW AND DOOR LOCK CONTROL SW LH B W–B W–B (W/G) IJ BUCKLE SW 16 W–B IH2 B 1 : * 4 EX. C/P B 2 : * 3 EX. C/P B18 : * 3 C/P B W–B W–B DOOR LOCK CONTROL RELAY POWER SEAT SW B 1 : EX. C/P B18 : C/P W–B SHIFT LOCK ECU B W–B O/D MAIN SW J2 JUNCTION CONNECTOR IF 5 W–B DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH W–B IO1 C C W–B (W/O POWER SEAT) W–B C W–B C W–B (W/ POWER SEAT) LIGHT FAILURE SENSOR W–B C REAR COMBINATION LIGHT LH W–B C BUCKLE SW AUTO ANTENNA MOTOR AND RELAY REAR WIPER RELAY J5 JUNCTION CONNECTOR C W–B BX1 3 W–B W–B FUEL PUMP 5 W–B Bb1 W–B W–B REAR COMBINATION LIGHT RH W–B BL (W/G) BQ (W/G) W–B 3 Bc1 W–B REAR WIPER MOTOR 4 Bd3 REAR COMBINATION LIGHT LH W–B W–B B38 W–B B38 W–B W–B B38 W–B REAR COMBINATION LIGHT RH W–B HIGH MOUNT STOP LIGHT W–B LUGGAGE COMPARTMENT LIGHT SW B W–B W–B W–B W–B LICENSE PLATE LIGHT BR (W/G) REAR WINDOW DEFOGGER(–) BS (W/G) 257 GROUND POINT W–B FRONT CLEARANCE LIGHT RH W–B FRONT SIDE MARKER RH W–B W–B (* 1) E4 W–B FRONT TURN SIGNAL LIGHT RH W–B (* 1) E6 W–B (* 1) I25 W–B W–B W–B W–B W–B (* 1) E4 W–B W–B (* 2) FRONT SIDE MARKER LH W–B E4 W–B (CANADA) 5 EB1 W–B HEADLIGHT LO LH W–B 7 7 DAYTIME RUNNING LIGHT NO. 4 W–B E4 7 W–B (5S–FE) 2 4 W–B 2B 2E W–B E3 W–B W–B EFI MAIN RELAY EB W–B (5S–FE) W–B E5 (5S–FE) W–B OXYGEN SENSOR RADIATOR FAN RELAY NO. 2 5 RADIATOR FAN RELAY NO. 3 2 EA1 W–B W–B (5S–FE) WATER TEMP. SW (FOR COOLING FAN) W–B E5 NOISE FILER (FOR IGNITION SYSTEM) 5 W–B W–B E5 ENGINE CONTROL MODULE (ENGIN AND ELECTRONIC (E1) CONTROLLED TRANSMISSION ECU) (A/T) ENGINE CONTROL MODULE (ENGINE ECU) (M/T) CRUISE CONTROL ACTUATOR ENGINE MAIN RELAY W–B HEADLIGHT LO RH (GND) ABS ACTUATOR AND ECU DAYTIME RUNNING LIGHT RELAY NO. 3 W–B RADIATOR FAN MOTOR W–B W–B FRONT TURN SIGNAL LIGHT LH ABS ECU (GND) 7 W–B E4 (E) EA W–B W–B W–B FRONT CLEARANCE LIGHT LH ABS RELAY E4 W–B FRON WIPER MOTOR ABS ACTUATOR BR W–B E5 A/C SINGLE PRESSURE SW (1MZ–FE) BR (5S–FE) BR 3 3D E17 BR 13 BR I9 BR I9 DATA LINK CONNECTOR 2 (TDCL) BR BR BR 3D BR DATA LINK CONNECTOR 1 (CHECK CONNECTOR) COMBINATION METER 12 3D W–B BR EC 258 (5S–FE) ED 3 BX1 BR W–B IP3 BR BR BR BR 16 IJ1 BR BR 18 (5S–FE) W–B FUEL SENDER ENGINE CONTROL MODULE (ENGINE (E01) AND ELECTRONIC CONTROLLED TRANSMISSION ECU)(A/T) (E02) ENGINE CONTROL MODULE (ENGINE ECU)(M/T) NOISE FILTER (FOR IGNITION SYSTEM) IGNITER HEATED OXYGEN SENSOR (BANK 1 SENSOR 1) W–B W–B 3 3D E14 I7 BR 3 3D BR BR I9 DATA LINK CONNECTOR 1 (CHECK CONNECTOR) BR DATA LINK CONNECTOR 2 BR DATA LINK CONNECTOR 3 BR I9 BR BR BR HEAD OXYGEN SENSOR (BANK 2 SENSOR 1) BR BR COMBINATION METER 12 3D IJ1 BR BR BR 18 3 BR BX1 A A J7 JUNCTION CONNECTOR BR A (E01) ENGINE CONTROL MODULE ENGINE (E02) AND ELECTRONIC CONTROLLED TRANSMISSION ( ECU) (E03) BR W–B BR BR BR BR BR ED (1MZ–FE) BR BR EC (1MZ–FE) BR BR I18 5 IQ1 5 BX1 W–B HIGH MOUNT STOP LIGHT (W/ REAR SPOILER) BUCKLE SW W–B B16 COOLING AFN ECU BUCKLE SW RH W–B W–B ENGINE CONTROL MODULE ENGINE (E1) AND ELECTRONIC CONTROLLED TRANSMISSION (ECU) BR HEATED OXYGEN SENSOR (BANK 1 SENSOR 2) W–B FUEL PUMP FUEL SENDER W–B REAR COMBINATION LIGHT RH W–B REAR COMBINATION LIGHT LH W–B HIGH MOUNT STOP LIGHT W–B (W/O POWER SEAT) W–B W–B 5 IO1 AUTO ANTENNA MOTOR AND RELAY W–B BL W–B B25 W–B B25 W–B 7 BZ1 W–B B28 (S/D, C/P) B28 (S/D, C/P) W–B W–B B BN (S/D, C/P) W–B LIGHT FAILURE SENSOR W–B REAR COMBINATION LIGHT LH W–B LICENSE PLATE LIGHT LH W–B W–B BM REAR WINDOW DEFOGGER(–) (W/O REAR SPOILER) W–B BUCKLE SW LH 4 Ba1 W–B (W/ POWER SEAT) W–B BUCKLE SW W–B B16 W–B POWER SEAT SW BO B28 REAR COMBINATION LIGHT RH (S/D, C/P) 259 GROUND POINT * 1 : TMC MADE * 2 : TMM MADE : PARTS LOCATION CODE SEE PAGE CODE SEE PAGE J1 33 J5 36 (W/G) J2 33 J7 33 : RELAY BLOCKS CODE SEE PAGE RELAY BLOCKS (RELAY BLOCK LOCATION) 1 25 R/B NO. 1 (LEFT KICK PANEL) 4 25 R/B NO. 4 (RIGHT KICK PANEL) 5 26 R/B NO. 5 (ENGINE COMPARTMENT LEFT) 6 26 R/B NO. 6 (BEHIND GLOVE BOX) 7 27 R/B NO. 7 (NEAR THE BATTERY) : JUNCTION BLOCK AND WIRE HARNESS CONNECTOR CODE SEE PAGE JUNCTION BLOCK AND WIRE HARNESS (CONNECTOR LOCATION) 1C 1F 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 20 (*1) ROOF WIRE AND J/B NO. 1 (INSTRUMENT PANEL) TMC MADE 20 (*2) COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL) TMM MADE 20 COWL WIRE AND J/B NO. 1 (INSTRUMENT PANEL LEFT) 22 ENGINE ROOM MAIN WIRE AND J/B NO NO. 2 (ENGINE COMPARTMENT LEFT) 22 COWL WIRE AND J/B NO. 2 (ENGINE COMPARTMENT LEFT) 24 COWL WIRE AND J/B NO NO. 3 (BEHIND COMBINATION METER) 1G 1I 1M 2B 2E 2F 3A 3B 3C 3D : CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS CODE EA1 EB1 SEE PAGE 38 (1MZ–FE) 38 (1MZ–FE) 40 (5S–FE) JOINING WIRE HARNESS AND WIRE HARNESS (CONNECTOR LOCATION) ENGINE ROOM MAIN WIRE AND ENGINE ROOM NO. 3 WIRE ENGINE ROOM MAIN WIRE AND RELAY WIRE IH2 42 FRONT DOOR LH WIRE AND INSTRUMENT PANEL WIRE IJ1 42 FLOOR NO. 1 WIRE AND COWL WIRE IK1 42 COWL WIRE AND A/C SUB WIRE IL1 42 COWL WIRE AND SERVO MOTOR SUB WIRE IM2 42 INSTRUMENT PANEL WIRE AND CONSOLE BOX WIRE IO1 42 FLOOR NO. 1 WIRE AND SEAT WIRE IP3 44 ENGINE WIRE AND COWL WIRE IQ1 44 ENGINE WIRE AND INSTRUMENT PANEL WIRE IT1 44 FRONT DOOR RH WIRE AND INSTRUMENT PANEL WIRE IV1 44 ROOF WIRE AND COWL WIRE IV2 44 ROOF WIRE AND COWL WIRE MADE IN USA 46 (S/D) BX1 48 (C/P) FUEL GAUGE WIRE AND FLOOR NO. 1 WIRE 50 (W/G) BZ1 Ba1 46 (S/D) 48 (C/P) 46 (S/D) 48 (C/P) LUGGAGE ROOM NO. NO 1 WIRE AND FLOOR NO. NO 1 WIRE FLOOR NO. NO 1 WIRE AND LUGGAGE ROOM NO. NO 2 WIRE Bb1 50 (W/G) LUGGAGE ROOM NO. 1 WIRE AND FLOOR NO. 1 WIRE Bc1 50 (W/G) BACK DOOR NO. 1 WIRE AND FLOOR NO. 1 WIRE Bd3 50 (W/G) BACK DOOR NO. 1 WIRE AND BACK DOOR NO. 2 WIRE 260 CODE SEE PAGE : GROUND POINTS CODE EA EB EC ED IE SEE PAGE 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) GROUND POINTS LOCATION FRONT RIGHT FENDER FRONT LEFT FENDER INTAKE MANIFOLD RH INTAKE MANIFOLD LH 42 LEFT KICK PANEL IG 42 INSTRUMENT PANEL BRACE LH IH 42 INSTRUMENT PANEL BRACE RH 42 RIGHT KICK PANEL IF II IJ BK 46 (S/D) 48 (C/P) ROOF LEFT 46 (S/D) BL 48 (C/P) 50 (W/G) BM BN BO UNDER THE LEFT QUARTER PILLAR 46 (S/D) 48 (C/P) 46 (S/D) 48 (C/P) 46 (S/D) 48 (C/P) UNDER THE RIGHT QUARTER PILLAR LEFT QUARTER PILLAR BP 50 (W/G) BACK PANEL CENTER BQ 50 (W/G) LOWER BACK PANEL CENTER BR 50 (W/G) BACK DOOR CENTER BS 50 (W/G) BACK DOOR RIGHT : SPLICE POINTS CODE E3 E4 E5 SEE PAGE WIRE HARNESS WITH SPLICE POINTS 38 (1MZ–FE) B2 40 (5S–FE) 38 (1MZ–FE) 40 (5S–FE) 38 (1MZ–FE) CODE B4 ENGINE ROOM MAIN WIRE B5 B11 40 (5S–FE) SEE PAGE 46 (S/D) 50 (W/G) 46 (S/D) 46 (S/D) 50 (W/G) WIRE HARNESS WITH SPLICE POINTS FRONT DOOR LH WIRE ROOF WIRE FRONT DOOR RH WIRE 38 (1MZ–FE) B16 46 (S/D) LUGGAGE ROOM NO. 2 WIRE 40 (5S–FE) B18 48 (C/P) FRONT DOOR LH WIRE E14 38 (1MZ–FE) B21 48 (C/P) ROOF WIRE E17 40 (5S–FE) 48 (C/P) FLOOR NO. NO 1 WIRE B27 48 (C/P) FRONT DOOR RH WIRE B28 48 (C/P) LUGGAGE ROOM NO. 1 WIRE 50 (W/G) ROOF WIRE 50 (W/G) BACK DOOR NO. 2 WIRE E6 ENGINE WIRE I5 B26 I7 I9 44 COWL WIRE I13 B30 I14 I18 B1 B25 B31 44 46 (S/D) 50 (W/G) ENGINE WIRE FRONT DOOR LH WIRE B32 B38 261 OVERALL ELECTRICAL WIRING DIAGRAM 262 HOW TO USE THIS MANUAL System Title Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black L = Blue R = Red BR = Brown LG = Light Green V = Violet G = Green O = Orange W = White GR = Gray P = Pink Y = Yellow Junction Block (The number in the circle is the J/B No. and connector code is shown beside it). Junction Blocks are shaded to clearly separate them from other parts (different junction blocks are shaded differently for further clarification.). Example: The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Indicates the connector to be connected to a part (the numeral indicates the pin No.) The position of the parts is the same as shown in the wiring diagram and wire routing. Indicates the pin number of the connector. The numbering system is different for female and male connectors. Indicates related system. Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows Outside numerals are pin numbers. is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. Indicates a shielded cable. The numbering system for the overall wiring diagram is the same as above. Indicates a Relay Block. No Shading is used and only the Relay Block No. is shown to distinguish it from the J/B. Indicates and located on ground point. The same code occuring on the next page indicates that the wire harness is continuous. 263 1994 Model (Location No. 1 to 36) 3–1 (1MZ–FE) 4–1 (5S–FE A/T and California M/T) 5–1 (5S–FE Ex. A/T and California M/T) Rear Window Defogger 24–4 (W/G) 28–1 (S/D,C/P) Rear Wiper and Washer 22–2 8–3 (for USA) 10–1 (for Canada) Remote Control Mirror 20–1 Horn 18–4 Shift Lock Illumination 15–2 SRS (Supplemental Restraint System) Interior Light 11–1 (S/D, C/P w/ Key Illuminated Entry) 12–1 (W/G w/ Key Illuminated Entry) 13–1 (S/D, C/P w/o Key Illuminated Entry) 14–1 (W/G w/o Key Illuminated Entry) ABS (Anti–Lock Brake System) 25–2 (TMC Made) 26–2 (TMM Made) Engine Control Air Conditioning 35–1(Lever Con– trol SW Type) 36–1(Push Con– trol SW Type) Front Wiper and Washer 18–2 Headlight Auto Antenna 27–3 (W/G) 28–3 (S/D,C/P) Back–Up Light Back Door Lock (w/o Power Window) Charging 6–7 (1MZ–FE) 7–7 (5S–FE) 22–4 (W/G) 2–4 Cigarette Lighter and Clock 22–3 Combination Meter 33–1 Cruise Control 24–2 Power Seat 21–3 Door Lock 19–1 Power Source 1~36–1 Electrical Controlled Transmission and A/T Indicator 6–2 (1MZ–FE) 7–2 (5S–FE) Power Window 20–2 Electrically Controlled Hydraulic Cooling Fan 27–2 (1MZ–FE) Radiator Fan and Condenser Fan Electric Tension Reducer 36–7 Radio and Player Light Auto Turn Off Moon Roof 34–2 23–2 23–3 Starting and Ignition 1–2 (1MZ–FE) 2–2 (5S–FE) Stop Light 8–1 (W/G) 9–1 (S/D, C/P) Taillight 16–1 (S/D, C/P) 17–1 (W/G) Turn Signal and Hazard Warning Light 9–3 (S/D, C/P) 18–2 (W/G) Unlock and Seat Belt Warning 34–1 21–1 34–3 (5S–FE) 29–1(S/D, C/P 6 Speaker) 30–1(W/G 8 Speaker) 31–1(S/D, C/P 4 Speaker) 32–2(W/G 6 Speaker) OVERALL ELECTRICAL WIRING DIAGRAM 264 SYSTEM INDEX 1 CAMRY ELECTRICAL W IRING DIAGRAM Starting and Ignition (1MZ–FE) Power Source 1 3 2 4 IGNITER I 2 A DARK GRAY 2 2H B–W (A/T) From Diode (for Cruise Control) <24–1> 8 1G 1 ST1 7 B–W 6 1G W–R 5 1E B–W 10A STARTER 1 EF1 4 5 S4 2 1 2 2 1 2 B–O B–O B–O 1 I21 IGNITION COIL NO. 6 2 1 B–O I20 IGNITION COIL NO. 5 1 B–O 1 2 1 A 2 A 3 A 4 A 5 A 6 A 7 A COIL1 COIL2 COIL3 COIL4 COIL5 COIL6 IGT4 IGT5 IGT6 3 B 2 B 1 B G–R IGT3 4 B R–B IGT2 5 B L–B IGT1 6 B GR–B IGF 8 B Y–R TACH 8 A W–G GND B–O B–O B W–B W–B W–B 1 A To Data Link Connector 1 (Check Connector)<3–3> To Engine Control Module (Engine and Electronic Controlled Transmission ECU)<3–7> S 3 A BLACK A , I15 IGNITER 1 1M STARTER BATTERY 8 P I2 11 1C +B 1 B B–R 7 LG–B 2 N1 NOISE FILTER (for Ignition System) 7 B FL MAIN 2. 0L 6 G 1 W–B B–R To Bulb Check Relay [COMB. METER] To Engine Control Module (Engine and Electronic Controlled Transmission ECU) To Circuit Opening Relay<3–2> 100A ALT B 5 W B–O FUSE BOX 1 B 1 B 4 GR B–O B F10 A FUSE BOX 3 B–O 6 18 3C B B–O B–O 2 2C B–O 6 3C B–R F10 A , F16 2 L W–B B–W B–R B–W W 1 A P1 PARK/NEUTRAL POSITION SW (NEUTRAL START SW) (A/T) N 5 2C 1 2F 20 3B 1 16 IP1 I17 IGNITION COIL NO. 2 2 2 3C 2 3D 8 5 P 3 3 EF1 7 I15 B BLACK I16 IGNITION COIL NO. 1 W 1 STARTER RELAY 17 IP1 6 B S3 A ,S4 STARTER B F16 B 1 1 Instrument panel brace LH IG EC Intake manifold RH OVERALL ELECTRICAL WIRING DIAGRAM B–W 1 5 W–R 1 1 1E 4 B–O To Injector <3–2> W–R I12 IGNITION SW 3 B–W 40A AM1 40A MAIN 5 W–R ST2 W–R 2 30A AM2 1 B–O IG2 9 B–O 2 6 1A B 10 AM2 9 1G 14 1A B–O 1 2G B–R I19 IGNITION COIL NO. 4 IG1 I18 IGNITION COIL NO. 3 4 AM1 B–W W B ACC Starting and Ignition (5S–FE) From Diode (for Cruise Control) <24–1> B–W 8 1G 14 1A 6 1G 1 7. 5A ALT–S 2 3C 2 2 5 2C 1 2F B–R W W 1 B (5S–FE) 20 3B B–W B–W W 2 3D 1 A (1MZ–FE) 6 3C B (M/T) B–R 6 B (A/T) B–O B–R W–R 1 2 G2 (*1) NE–(*2) 1 2 4 3 (*1) 1 4 3 2 (*2) B–R IG– 1 2 4 R–L E Y (Canada) E 1 B L L B A B STARTER Instrument panel brace LH IG EC Intake manifold RH G1 To Data Link Connector 1 (Check Connector) <4–7><5–3> To Tachometer To Engine Control Module (Engine and Electronic Controlled Transmission ECU)<4–8> To Engine Control Module (Engine ECU)<5–4> W–B W–B A , S4 E S B S4 B S3 2 IP3 10 IP3 B BATTERY 1 8 IG B STARTER S 3 A BLACK B R 11 A Y 1 FL MAIN 2. 0L IGF IGT 3 +B I2 IGNITER B F16 C 5 C– W 2 D2 DISTRIBUTOR NE G1 G– NE+ G+ G– W–R B–R 1 N1 NOISE FILTER 1 1M 9 Y W–B 11 1C W–R B 1 B I3 IGNITION COIL P1 PARK/NEUTRAL POSITION SW(NEUTRAL START SW) (A/T) To Engine Control Module (Engine and Electronic Controlled Transmission ECU)<4–7> To Engine Control Module (Engine ECU)<5–4> (5S–FE) F10 B B–R FUSE BOX To Bulb Check Relay F16 C 1 C (*3) B , To Circuit Opening Relay <4–3><5–1> F10 A , W–R N 1 EF1 18 3C 100A ALT P W–B 3 EF1 2 2C 16 IP1 5 6 1D Y W 1 17 IP1 3 1 EF1 C9 CHARGE WARNING LIGHT [COMB. METER] B–W FUSE BOX (1MZ–FE) F10 A 1 J1 JUNCTION CONNECTOR 5 10A GAUGE 3 1D B–W (A/T) 1 1 1 1E 7. 5A IGN B–W 4 C7 CLUTCH START SW(M/T) B–W B (M/T) (M/T) I12 IGNITION SW 5 1E 10A STARTER W–R 40A AM1 *1 : California *2 : Ex. California *3 : One Body Assembly Ex. California R–L ST2 W–R 2 40A MAIN W–R 5 IG2 9 B–O W–R 10 AM2 9 1G 3 1G 6 1A ST1 7 B–W 30A AM2 W W 6 2C To Daytime Running Light Relay(Main) <10–2> W 2 2H Y 1 2G B–R B–W B–Y W IG1 2 B ACC 4 AM1 W 4 3 2 B–Y 1 C harging W Power Source 1 2 3 A , G2 B GENERATOR (ALTERNATOR) GENERATOR (ALTERNATOR) G1 A G 2 B BLACK 1 1 2 3 OVERALL ELECTRICAL WIRING DIAGRAM 2 C AM RY (Cont. next page) 3 C AM R Y Engine Control (1MZ–FE) P o w e r S o urce 1 1 1 1 1 OX1 B–O R–L C9 BR 18 3D WA 4 22 19 A A (SHIELDED) BR R–L G–R G–R B–O G R L GR Y W (SHIELDED) BR 1 EB Instrument panel brace LH IG GR Y W R L W–B W–B Front left fender BL Under the left quarter piller 7 3D 19 IP1 G 1 1M G–R A , C10 B BR (SHIELDED) BR 3 B BR 16 E1 3 G–R TS 11 16 IP1 OX2 J7 JUNCTION CONNECTOR TC 6 MALFUNCTION INDICATOR LAMP(CHECK ENGINE WARNING LIGHT) J2 JUNCTION CONNECTOR R–L R–L To ABS ECU<25–2> <26–3> B–Y R–L G–W 15 B BR 2 12 6 A G–R 2 G–R 2 B–O B–O 2 I9 INJECTOR NO. 6 B–O 2 I8 INJECTOR NO. 5 B–O B–O B–O B–O I7 INJECTOR NO. 4 1 B–O I6 INJECTOR NO. 3 W–B BATTERY 11 1C 2 B–O B–O I4 INJECTOR NO. 1 W–B 18 3C I5 INJECTOR NO. 2 FL MAIN 2. 0L B–O 9 IP1 TE2 12 3D BR B–O 2 TE1 B W–B B 11 IP1 8 (Short Pin) FP OPT L–B 13 3A WB From Igniter <1–3> W–B 4 BX1 W–B 1 B B L–B 1 C 1 IP1 23 AB 5 BX1 FUSE BOX 5 R–G B 15 IP3 16 IJ1 G–R B–O B–O B–O F10 A , F16 5 D1 DATA LINK CONNECTOR 1 (CHECK CONNECTOR) B–Y L–B 4 M 1 A L–B L–B 2 F15 FUEL PUMP 3 3 2C 2 2B 2 2H 6 G–R LG–R 6 To Center Airbag Sensor Assembly<23–4> To ABS ECU<25–3><26–3> To Cruise Control ECU<24–2> 6 From Center Airbag Sensor Assembly <23–4> 1 C 3 3D L–W 1 4 12 To ABS ECU <25–3><26–3> B–O B–O To Igniter <1–3> 5 6 BR AB CIRCUIT OPENING RELAY W–B 15A EFI EFI MAIN RELAY 2 2D W 30A AM2 7. 5A OBD 1 1E 10A GAUGE 6 1B 3 E1 From Cooling Fan ECU <27–2> 4 2D 2 IM1 B G–L 10 A/D 2 B–O W–R 1 2G B–O B 3 2D 18 IP1 G–W GR–B TC 9 1D 1 W 4 Y–B 3 1G R–Y 3 100A ALT From Cruise Control ECU<24–3> 6 B–Y B–O 6 G–B 14 ABS From ABS ECU <25–3><26–3> 6 1A 2 3 EF1 From ABS ECU <25–2><26–2> From Center Airbag Sensor Assmbly<23–4> B–O B–O From ABS ECU <25–2><26–3> (SHIELDED) 9 1G 4 IP1 B–W W–G 7. 5A IGN I12 IGNITION SW B–O B W–R W 8 1G B–O D3 DATA LINK CONNECTOR 2 (TDCL) R–L B–O From ” STARTER” Fuse<1–1> IG2 9 ST2 40A AM1 R–L W–G B–W BR B B–O GR–B G–W BR BR B–O W–G IG1 2 ST1 7 10 AM2 4 B–Y ACC 4 AM1 3 2 B–W B * Engine Control Module(Engine and Electronic Controlled Transmission ECU) * Malfunction Indicator Lamp(Check Engine Warning Light) Intake manifold LH ED Intake manifold RH EC For the connectors of the parts listed below, see the next page. * Fuse Box Engine Control (1M Z–FE) * Malfunction Indicator Lamp(Check Engine Warning Light) BR 12 3D BR 16 IP3 BR 2 BR L–W Y–L W–L R NE NE– B 17 1 2 4 EE1 EE1 EE1 2 C 21 A A 16 34 A 33 28 3 F A A BR A A 1 K1 KNOCK SENSOR 2 W 1 2 1 8 1C 5 1M BR 2 BR K2 KNOCK SENSOR 1 W 1 5 3D W–B A A F W–B A 5 3C W–B A J7 JUNCTION CONNECTOR W–B BR A A G (SHIELDED) J1 JUNCTION CONNECTOR G 3 EE1 D 6 5 W–B 16 NC2+ ELS E1 EO1 EO2 EO3 B B–R 14 (SHIELDED) 1 2 9 B BR 15 A 1 R–B From Stop Light SW <8–2><9–2> L–B B–Y B B R 10 (SHIELDED) (SHIELDED) B–R J6 JUNCTION CONNECTOR A B–O 4 B G G D6 DIODE (for Idle–Up) B L 9 L–W L–R B 8 G22+ G22– KNKR KNKL A G A 2 To Cooling Fan ECU<27–2> To Cruise Control ECU<24–2> To Cooling Fan ECU<27–2> To Tachometer BR B–W E1 EGR GAS TEMP. SENSOR 7 C W–B BR 6 A 7 8 B From ’ TAIL’ Fuse <16–2><17–2> 5 IQ1 5 A 21 B BR 1 BR 6 A 24 D O6 O/D DIRECT CLUTCH SPEED SENSOR 1 2 5 G B–O 12 A 22 B 2 (SHIELDED) 4 IQ1 B–O A 25 A 32 A B–O B–O 12 C 7 B 3 TACO VTA1 E2 STP THA VG VG– NC2– VCC IDL1 ENGINE CONTROL MODULE(ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) W 3 22 C , E10 D ACIS #60 #50 #40 #30 #20 #10 C 1 B W 1 B–O G–R 4 E1 A 2 V4 VSV(for Intake Control) 3 3D OX FPU D 11 IM1 B–O H9 HEATED OXYGEN SENSOR (Bank 1 Sensor 2) 1 2 B–O HT +B SP1 A 23 THG B ,E9 V–Y 22 THW A , E8 To Combination Meter<33–2> 23 BATT E7 EGR RSC A V3 VSV(for Fuel Pressure Up) 12 D Y–B 29 D I1 IDLE AIR CONTROL VALVE(ISC VALVE) From Igniter <1–4> 30 A G–B 26 NSW ACT RSO +B +B1 A B–O 15 A B–O 16 IGF IGT6 A G–R 3 BR A V2 VSV(for EGR) 20 IP1 P–B B 9 II1 8 II1 (SHIELDED) 10 II1 24 IGT5 IGT4 A Y–R G–R B P–B 18 W–G 3 G–R 25 26 (SHIELDED) IGT3 IGT2 A G–R B W–R FC C L–B W D GR–B HTS D R–B IGT1 OXS B–W A/C ACV 13 D THA VG VG– (SHIELDED) TE1 14 C G–W B–W TE2 20 B E2 4 L STA 14 D 4 3B L SDL BR B–W HTR 14 A L L C18 CRANKSHAFT POSITION SENSOR OXR 5 D 2 C17 CAMSHAFT POSITION SENSOR HTL 20 D 3 W OXL 1 C 2 4 M6 MASS AIR FLOW 1 (AIR FLOW METER) B W C 1 W D 2 Y A L D 1 GR C R B W–L 5 C LG–B 12 IP3 G 11 B T1 THROTTLE POSITION 1 SENSOR G–Y W–L 13 W–G To A/C Aeplifier <35–4><36–5> GR–B 1 EF1 18 IP3 28 2 E4 ENGINE COOLANT TEMP. SENSOR(EFI WATER TEMP. SENSOR) B–O V1 VSV (for A/C Idle–Up) W–B 11 13 From STARTER Fuse<1–2> B BR 15 5 1E B–L 10 6 1G R–Y 19 1 B–Y R–L V–R R–L (SHIELDED) 1 SDL G–W 3 13 SG CG B–W HT 12 BATT B–W 1 OX 1 (SHIELDED) 3 2 +B W HT 4 E D24 DATA LINK CONNECTOR 3 OX B–O 2 +B (SHIELDED) L–B B–O 4 E H11 HEATED OXYGEN SENSOR (Bank 1 Sensor 1) R–L B–R H12 HEATED OXYGEN SENSOR (Bank 2 Sensor 1) B–R R–L A G–B A B–O B–O BR B–W J6 JUNCTION CONNECTOR BR A R–L BR R–L G–R G–R B–O G R L GR Y W 8 G–W R–L W–G B–W BR B B–O GR–B G–W BR 7 W–B B–O 6 BR 5 (SHIELDED) (SHIELDED) (SHIELDED) (SHIELDED) BR BR Intake manifold LH ED Left kick panel IE OVERALL ELECTRICAL WIRING DIAGRAM (Cont. next page) 3 CAMRY (Cont’ d) 3 CAMRY (Cont’ d) Engine Control (1MZ–FE) 9 11 10 FUSE BOX F10 A F16 B 1 ENGINE CONTROL MODULE (ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) E 7 A DARK GRAY E 8 B DARK GRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 15 16 7 8 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12 13 14 15 16 17 31 32 33 34 18 19 20 21 22 E 9 C DARK GRAY 1 2 3 4 5 6 1 2 3 4 5 6 7 8 7 8 9 10 11 12 13 14 15 16 MALFUNCTION INDICATOR LAMP (CHECK ENGINE WARNING LIGHT) [COMB. METER] C9 A 1 2 3 4 5 6 7 8 C10 B GRAY 9 10 11 12 13 14 15 16 E10 D DARK GRAY 1 2 3 4 5 6 7 8 9 10 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 12 Engine Control (5S–FE A/T and California M/T) P ower Source 1 *1 : California *2 : Ex. California 3 2 4 B–Y ACC 2 2H B–O 18 IP1 B–O 2 2D 40A AM1 1 B–O 1 5 B–O 4 IP1 B–O EFI MAIN RELAY 1 1E W FUSE BOX F10 A B–O C 3 F16 B B–W 6 2 C 2 3 1 3 EF1 W–B L–B G–R 13 3A 15 IP3 B–O L–B Y G–R 7 3D L–B 16 IJ1 19 3D L–B W–B R–L (*1) G–R L–B Y 4 BX1 R–B(*1) Y (*2) 4 R–B (*1) F15 FUEL PUMP M W 18 3C Y W–B I7 INJECTOR NO. 4 2 1 W–R 6 R–L(*1) 11 1C R–B(*1) 5 W–B W–B BATTERY W–B 5 BX1 Front right fender EB Under the left quarter pillar BL C9 A 1 1M MALFUNCTION INDICATOR LAMP (CHECK ENGINE WARNING LIGHT) [COMB. METER] C10 B GRAY W–B FL MAIN 2. 0L I5 INJECTOR NO. 2 2 1 W–R 3 B 18 3D Y (*2) W–R B 6 W (*2) W–R R–L(*1) W (*2) A , C10 B 6 G–R B 1 B 4 6 W W FUSE BOX I6 INJECTOR NO. 3 2 1 W–R 1 L–B B C9 MALFUNCTION INDICATOR LAMP (CHECK ENGINE WARNING LIGHT) [COMB. METER] G–R B–O W 100A ALT F10 A , F16 I4 INJECTOR NO. 1 2 1 W–R 6 A CIRCUIT OPENING RELAY 9 IP1 W–R 1 A J2 JUNCTION CONNECTOR 6 3 2C 2 2B 1 B–O W–R I12 IGNITION SW 6 1B From ” STARTER” Fuse<2–1> 9 1D R–L 9 1G 6 1A B–W R–L 4 2D 1 2G B–W B–O ST2 10A GAUGE 7. 5A IGN B–W IG2 9 15A EFI W–R W 30A AM2 W–R 10 AM2 2 3 1G B–O ST1 7 B 8 1G W–G IG1 2 W–G 4 AM1 B–W (Ex. California M/T) B–W IG Instrument panel brace LH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 OVERALL ELECTRICAL WIRING DIAGRAM (C ont. next page) 4 C AM R Y 4 CAMRY (Cont’ d) *1 : *2 : *3 : *4 : Engine Control (5S–FE A/T and California M/T) 8 7 6 ENGINE CONTROL MODULE(ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) 12 13 14 15 16 17 18 19 20 21 22 5 B Y–G BR–B (A/T) L–B B–O G–R BR–B GR G–W R–W R–L W W 12 2 17 8 9 13 15 4 1 EC Intake manifold RH TE2 VF1 TC OX2 OX1 IG– 11 19 1 IDL L R L B VTA IDL E02 26 A 2 From Distributor <2–3> 1 K1 KNOCK SENSOR W–B BR 5 B TE1 LG–R 16 TT From SRS Warning Light [COMB. METER] <23–4> To Cruise Control ECU<24–2> To Center Airbag Sensor Assembly<23–4> To ABS ECU <25–3><26–3> From Igniter <2–3> 3 W B–Y E1 DATA LINK CONNECTOR 1 TS(CHECK CONNECTOR) AB To ABS ECU <25–3><26–3> G–O To O/D Main SW<7–5> B D1 R–G G–B FP BR 9 From ABS ECU <25–2><26–3> Intake manifold LH W–B 14 Y–B ED 16 IP3 ECT 4 G–L 12 3D W–B TT 10 From Cruise Coutrol ECU <24–3> To Center Airbag Sensor Assembly<23–4> To ABS ECU <25–2><26–3> 3 3D B–Y W–B R–B(*1) 12 From SRS Warning Light [COMB. METER] <23–4> R–L(*1) W D3 ENG TE2 TE1 DATA LINK CONNECTOR 2(TDCL) AB A/D TC ABS R–L G–W 1 O2 OXYGEN SENSOR (Sub) R–W 5 O3 OXYGEN SENSOR (Main) G–R (*4) 1 VTA BR R (SHIELDED) 2 E1 VC R–L 7 3 Y PIM 15 IP1 8 To Cruise Control ECU <24–2> 11 B 12 B 1 B G1 (*1) NE G2 G– G+ (*2) E01 NE+ NE– G– 4 A 5 A 17 A 18 A 13 A KNK 13 B 19 IP1 W E2 (SHIELDED) (A/T) G–R L–B 2 B THG B–O G–R 9 B 2 EC Intake manifold RH ED W–B W E1 14 A 10 B 3 L W–B OX2 6 B 4 W–B OX1 7 B THA VC R (SHIELDED) 13 IP3 THW VC 3 (SHIELDED) ENGINE CONTROL MODULE(ENGINE ECU)(M/T) 1 IP1 E21 2 PIM 2 Y B , E14 C TT IGT 3 B E2 1 B–Y W E11 A , E12 19 IP3 IGF 4 B ENGINE CONTROL MODULE(ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU)(A/T) 15 B B/K 16 B B , E10 C 14 B SPD 3 A 20 A FPU 8 B ACA W–R 4 C A ,E8 TE1 ACT 9 C E7 TE2 ELS G–W B–Y B–R 21 C 10 C V–Y 4 3B 2 2 1 B 2 T1 THROTTLE 1 POSITION SENSOR E2 BR 19 3C 1 BR M1 MANIFOLD ABSOLUTE PRESSURE SENSOR (VACUUM SENSOR) L 1 W G–W 15 1A BR BR BR (*2) E4 ENGINE COOLANT TEMP. SENSOR (EFI WATER TEMP. SENSOR) LG BR From Igniter <2–3> To Combination Meter <33–2> To A/C Amplifier <35–4><36–5> To A/C Amplifier <35–4><36–5> P 6 1M BR I10 INTAKE AIR TEMP. SENSOR (IN–AIR TEMP. SENSOR) L–B BR BR E1 EGR GAS TEMP. SENSOR BR GR From Stop Light SW<8–2><9–2> From ” MIR–HTR” Fuse<24–4><28–1> G 1 LG–B B–W (*3) B–W (*4) W–L 1 2 3 4 5 6 7 8 9 10 11 9 10 11 12 13 14 15 16 W G–R 1 2 3 4 5 6 7 8 BR G–R(*3) G–R 1 2 3 4 5 6 7 8 9 10 11 12 13 R–L Y R–L (*1) 25 A 24 A 3 2 C NSW (A/T) E10 C DARK GRAY (M/T) E14 C DARK GRAY EGR VF BATT (A/T) E 8 B DARK GRAY (M/T) E12 B DARK GRAY 14 15 16 17 18 19 20 21 22 23 24 25 26 (A/T) #40 5 3C 22 C BR–B #30 1 C GR # 20 ISCV 14 1A 1 G–W #10 ISCC 5 1E 12 IP3 8 A R–W ISCO 2 D6 DIODE (for Idle–Up) G V2 VSV(for EGR System) LG 23 A W G–R V1 VSV (for A/C Idle–Up) G–R 7 A 5 C 14 C 12 A 11 A G–R 1 9 A +B1 FC 2 R–B (*1) W 3 G–Y B–O I1 IDLE AIR CONTROL VALVE(ISC VALVE) +B 1 2 10 A B–O B–O B–W 11 C 12 C 13 C 1 5 3D B–R (*1) V3 VSV(for Fuel Pressure Up) 6 1G 2 (A/T) E 7 A DARK GRAY (M/T) E11 A DARK GRAY G–W 11 IP1 STA From ” TAIL” Fuse<16–2><17–2> G B–O B–O B–W B–O B–O B–O (*1) B–O B–O B–O B–O W–G W–G (Ex. California M/T) BR 5 B–W California Ex. California for Canada in TMM Made Ex. *3 Intake manifold LH Power S o u rce For the connectors of the parts listed below, see the next page. * Fuse Box * Engine Control Module(Engine ECU) * Malfanction Indicator Lamp(Check Engine Warning Light) Engine Control (5S–FE Ex. A/T and California M/T) 1 3 2 4 R–W From ” TAIL” Fuse<16–2><17–2> 6 C 3 10 B C 12 B OX2 E1 1 B 24 A A , C10 B MALFUNCTION INDICATOR LAMP (CHECK ENGINE WARNING LIGHT) [COMB. METER] R–L C9 G–R (*1) Y L 19 3D 7 3D G–R G–R G–R 12 8 C C ELS W 4 17 A A 18 A 5 A NE+ NE– G– G+ IGT KNK IGF B A W 5 B R IDL P From ” MIR–HTR” Fuse<24–4> <28–1> D6 DIODE(for Idle–Up) G L B B B–Y B–Y B 6 18 3D 1 2 R–L OX1 B P R BR E1 EGR GAS TEMP. SENSOR VTA G–R 3 6 1B From Distributor <2–3> 3 B 5 3C THA THG E2 PIM VC ACT ACA VTA IDL B , E14 C ENGINE CONTROL MODULE(ENGINE ECU) VF 8 L L–B BR I10 INTAKE AIR TEMP. SENSOR (IN–AIR TEMP. SENSOR) BR LG L R To A/C Amplifier <35–4><36–5> 11 2 B B 5 3D E01 SPD A 3 E02 C 22 A 11 A 13 26 Under the left quarter pillar Intake manifold RH EC 11 5 Intake EC manifold RH BR 3 W–B V–Y W–B To Combination Meter <33–2> From Igniter <2–3> W W–R G–R(*2) G–W Y–G W R–W 12 B–Y BR 2 14 3 3D 12 3D W–B 1 19 4 W–B 2 16 10 BR 3 Y 1 16 IP3 BR I7 INJECTOR NO. 4 1 G–B 1 1 From ABS ECU <25–2><26–3> From SRS Warning Light[COMB. METER] <23–4> 2 1 12 8 9 13 2 4 15 FP B TE1 TE2 VF1 W OX1 OX2 D 1 DATA LINK CONNECTOR 1 CHECK CONNECTOR) E1 TS IG TC AB 1 2 8 7 TE1 TE2 ENG W D 3 DATA LINK CONNECTOR 2(TDCL) A/D TC ABS AB E1 G–L Y (*1) From Cruise Control ECU<24–3> From Center Airbag Sensor Assembly<23–4> From ABS ECU <25–2><26–3> W–R O2 OXYGEN SENSOR(Sub) R–L L–B W–R 4 BX1 GR 1 I5 INJECTOR NO. 2 R–G 2 L–B W B–O (*1) W–R 19 IP3 Y–B 1 I6 INJECTOR NO. 3 L–B 13 IP3 BR 2 (*1) 19 IP1 W G–R(*3) 1 IP1 W–R K1 KNOCK SENSOR W–R 15 IP3 R–W G–W GR Y L–B G–R GR W G–R L–B F15 M FUEL PUMP 5 5 W–B BX1 BL TE2 7 B 2 3 2 B From Igniter G–W <2–3> To Cruise Control ECU<24–2> R–W To ABS ECU LG–R <25–3><26–3> To Center G–R Airbag Sensor Assembly W <23–4> From SRS B–Y R–L Warning Light [COMB. METER] O3 <23–4> OXYGEN SENSOR(Main) W IG 25 To ABS ECU <25–3><26–3> Instrument panel brace LH TE1 W–B W–B W–B EB E21 THW E11 A , E12 15 B I4 INJECTOR NO. 1 4 W–B BATTERY Front left fender 2 9 B 3 10A GAUGE G–R 16 IJ1 1 1M BATT A 12 6 11 1C EGR 4 13 3A 18 3C BR V2 VSV(for EGR System) B–O ISCV A 1 6 L–B FL MAIN 2. 0L 4 6 W–B From STARTER Fuse <2–1> B 6 1 16 C 4 3 1G R–L C 6 A VC E2 PIM VC W ISCO ISCC 23 A #10 #20 W–R B–W 2 FUSE BOX B–W B B F10 A , F16 3 6 13 B 1 G 1 A FC CIRCUIT OPENING RELAY W W–B 6 3 B 2 9 A C 1 A 4 B 1 R–W 10 A 2 Y W–R W–B B–O 3 2 T1 THROTTLE POSITION 1 SENSOR E2 BR BR M1 MANIFOLD ABSOLUTE PRESSURE SENSOR(VACCUM SENSOR) E4 ENGINE COOLANT TEMP. SENSOR (EFI WATER TEMP. SENSOR) BR 1 C STA +B +B1 3 EF1 1 1 2 G–W 7 C V1 VSV(for A/C Idle–Up) B–O B–O B–O W 2 A 4 IP1 2 1 BR B–W B–O B–O 1 1E B–O 1 2 G–R 2 3 2C 2 2B 1 B–O I1 IDLE AIR CONTROL VALVE(ISC VALVE) G–Y 3 11 IP1 B–O 40A AM1 *1 : SHIELDED *2 : TMC Made *3 : TMM Made W–R B–O B–O 1 W–L 9 IP1 B–O EFI MAIN RELAY 5 2 6 1A B–O W–R 9 1G 9 1D LG B–O 12 IP3 4 2D 18 IP1 2 2D 100A ALT BR ST2 I12 IGNITION SW 1 B BR B–R W–G 7. 5A IGN BR W 15A EFI To Cruise Control ECU <24–2> BR 30A AM2 IG2 9 W–G B–O ST1 10 AM2 J2 JUNCTION CONNECTOR C 8 1G LG–B 2 2H BR 1 2G BR IG1 2 R 4 AM1 BR W–R B B–Y B–Y ACC Intake manifold LH ED ED Intake manifold LH OVERALL ELECTRICAL WIRING DIAGRAM (C ont. next page) 5 CAMRY 5 CAMRY (Cont’ d) Engine Control (5S–FE Ex. A/T and California M/T) 5 7 6 8 FUSE BOX F10 A F16 B 1 1 ENGINE CONTROL MODULE(ENGINE ECU) E11 A DARK GRAY E12 B DARK GRAY 1 2 3 4 5 6 7 8 9 10 11 12 13 1 2 3 4 5 6 7 8 14 15 16 17 18 19 20 21 22 23 24 25 26 9 10 11 12 13 14 15 16 MALFUNCTION INDICATOR LAMP (CHECK ENGINE WARNING LIGHT)[COMB. METER] C9 A 1 2 3 4 5 6 7 8 C10 B 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 E14 C DARK GRAY 1 2 3 4 5 6 7 8 9 10 11 12 P ow er S o u rc e Electronic Controlled Transmission and A/T Indicator (1MZ–FE) 1 3 1 2G 8 1G 3 1G R–L 2 2H 6 1D ST2 2 R–L R–L W–G B–O R–Y B–O 18 IP1 15 16 12 IP3 +B OD1 12 D 14 A SP1 B ,E9 L–R V–Y 7 D BATT A , E8 C , E10 D ENGINE CONTROL MODULE(ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) 3 D NSW 2 D 10 D 15 D L P 2 6 D R OD2 9 10 11 SLN– 4 3 6 2 TE2 VC 11 D 1 B VTA 7 B E2 22 B IDL 32 A L See Engine Control System<3–5> See Engine Control System<3–8> FUSE BOX To Cruise Control ECU<24–2> F10 A F16 B B–O W–B E10 D DARK GRAY 1 2 3 4 5 6 7 8 To Cruise Control ECU<24–2> E2 ELECTRONIC CONTROLLED TRANSMISSION SOLENOID BATTERY 1 12 13 14 15 16 17 18 19 20 21 22 23 24 TE1 5 C 1 12 13 14 15 16 11 E1 16 C P–L 8 9 10 11 9 10 E03 28 A BR 7 E02 33 A W–B 5 6 E01 34 A W–B 1 2 3 4 SL W–B A E 9 C DARK GRAY S2 17 A 27 A L–Y B S1 3 A 11 A P–L A 20 21 22 P–L 18 19 J7 JUNCTION CONNECTOR 12 13 14 15 16 17 FL MAIN 2. 0L +B1 V 7 8 1 B 6 IP1 L–R To Combination Meter <33–4> E7 23 D 22 D 14 D 1 2 3 4 5 6 Y–G FUSE BOX B W–L B–O E 8 B DARK GRAY F10 A , F16 Y–B B–O B–O W 31 32 33 34 1 A 13 IP1 6 II1 11 IP1 17 18 19 20 21 22 23 24 25 26 27 28 29 30 R–B G–O 13 14 L–R O E6 ELECTRONIC CONTROLLED TRANSMISSION PATTERN SELECT SW 3 L–R IN1 L–R 11 12 3 EF1 W–B W 1 2 3 4 5 6 7 8 9 10 3 Y–L R–L L–R 4 2D B–O E 7 A DARK GRAY 6 POWER B–O 3 2 2D 3 2C 4 II2 See Engine Control System <3–6> 1 2 2B R–L To Cruise Control ECU<24–2> 1 8 1K EFI MAIN RELAY ENGINE CONTROL MODULE(ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) 1 1E 5 From Combination Meter <33–2> 2 I12 IGNITION SW 6 IN1 R–L 9 1D 40A AM1 R–L C R–B 9 1G 100A ALT 10A GAUGE O B–O 7. 5A IGN NORMAL IG2 9 15A EFI L–R J3 JUNCTION CONNECTOR C C W 10 AM2 30A AM2 B B W–R ST1 Y–L B–Y 4 L–R IG1 2 B–Y ACC 4 AM1 B–O 2 25 26 27 28 EB Front left fender Intake manifold LH ED OVERALL ELECTRICAL WIRING DIAGRAM (Cont. next page) 6 C AM RY 6 CAMRY (Cont’ d) Electronic Controlled Transmission and A/T Indicator (1MZ–FE) Back–Up Light (1MZ–FE) *1 : S/D, C/P 5 8 7 6 R–L R–L L–R 2 IP3 Y–L O R–L R–L P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW] (NEUTRAL START SW) (M/T) (A/T) R–L 2 2 B1 BACK–UP LIGHT SW (M/T) R–B 7 O R–B R R–B (M/T) R–B (W/G) 6 Bc2 R–B 3 Bd2 O 8 IQ1 14 IQ1 R–B (W/G) Y–L 7 IQ1 13 IQ1 5 II1 9 IQ1 L–R Y–L O B–O R R–B G–W 13 11 10 7 5 4 3 BACK–UP LIGHT [REAR COMB. LIGHT] 3 A (*1) 4 B (W/G) R11 A , B B 3 A (*1) 4 B (W/G) C11 A/T INDICATOR LIGHT [COMB. METER] W–B W–B (*1) W–B (W/G) 1 2 3 4 B J2 JUNCTION CONNECTOR B R11 RH W–B (*1) W–B (*1) 6 BACK–UP LIGHT [REAR COMB. LIGHT] R9 LH W–B (W/G) 9 G–O 4 A (*1) 3 B (W/G) P R N D 2 R9 A , B L O/D OFF POWER R–L 8 4 A (*1) 3 B (W/G) 1 2 3 4 W–B 3 R–B (*1) R–B R–B 10 IJ1 R–B G–O O5 O/D MAIN SW 1 From Combination Meter<33–4> R–B (A/T) 3 Ba1 R–B (*1) G–W 1 IP3 B–O O G–O G–O 1 IP3 Y–L II1 G–O 2 1 R–B (W/G) P 8 R–B (*1) R 9 R–B N 10 (M/T) D 3 R–B 2 4 G–O D L Y–L D J1 JUNCTION CONNECTOR G–O IF W–B (*1) W–B 4 Ba1 Left kick panel Back door center BR Under the left quarter pillar BL Electronic Controlled Transmission and A/T Indicator (5S–FE) P o w er So urc e *2 : w/o A/T Indicator Light 1 3 2 B 4 W–R B–Y ACC W 4 AM1 IG1 2 1 2G 2 2H B–Y R–L 3 1G 8 1G ST1 R–L L–R W–R 10 AM2 IG2 9 7. 5A IGN B–O 15A EFI 30A AM2 10A GAUGE R–L 6 1D Y–L ST2 9 1G 2 9 1D 8 1K R–L C C R–L C R–L 2 2D 12 C B 13 IP1 6 IP1 6 II1 ELECTRONIC CONTROLLED TRANSMISSION PATTERN SELECT SW E 2 A BLACK W–G E 3 B BLACK L–R L–R (*2) 1 2 1 2 3 13 C +B 20 C 1 C +B1 BATT 22 C 9 C OD1 SPD B , E10 C 6 C NSW 19 C 18 C P L 2 G–O A , E8 O E7 ENGINE CONTROL MODULE(ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) Y–L B–O B–O B E10 C DARK GRAY NOMAL L–R 9 10 11 12 13 14 15 16 1 B L–R 12 IP3 W–L F10 A , F16 11 IP1 3 IN1 L–R 4 2D B–O B 100A ALT 2 2B 3 2C 1 2 3 4 5 6 7 8 FUSE BOX 1 A 3 Y–B W 2 To Cruise Control ECU<24–2> EFI MAIN RELAY See Engine Control System<4–6> 14 15 16 17 18 19 20 21 22 23 24 25 26 3 EF1 E 8 B DARK GRAY From Combination Meter <33–2> 5 6 POWER 3 V–Y 1 R–L J3 JUNCTION CONNECTOR W B 1 2 3 4 5 6 7 8 9 10 11 12 13 6 IN1 L–R 4 II2 E 7 A DARK GRAY L–R R–L G–O E6 ELECTRONIC CONTROLLED TRANSMISSION PATTERN SELECT SW To Combination Meter<33–4> ENGINE CONTROL MODULE(ENGINE AND ELECTRONIC CONTROLLED TRANSMISSION ECU) 1 1E O 18 IP1 B–O 1 B–O I12 IGNITION SW 40A AM1 7 C OD2 1 A E01 P–L EB E02 7 B TE1 15 B TE2 14 B VF VC 8 B 1 B See Engine Control System (5S–FE, A/T)<4–6> B E2 NO. 2 NO. 1 LOCK–UP W BATTERY Front left fender 14 A BR 3 A TT 26 A W–B 1 B E1 13 A To Cruise Control ECU <24–2> S2 15 A P–L S1 2 A V SL 1 A L–Y W–B 12 13 14 15 16 17 18 19 20 21 22 W–B 1 2 3 4 5 6 7 8 9 10 11 FL MAIN 2. 0L A ,E3 VTA 11 B E2 9 B See Engine Control System (5S–FE, A/T)<4–6> B ELECTRONIC CONTROLLED TRANSMISSION PATTERN SELECT SW FUSE BOX F16 B F10 A Intake manifold LH ED EC Intake manifold RH IDL 12 B 1 1 OVERALL ELECTRICAL WIRING DIAGRAM (Cont. next page) 7 C AM R Y 7 CAMRY (Cont’ d) Electronic Controlled Transmission and A/T Indicator (5S–FE) 5 Back–Up Light (5S–FE) 8 7 6 R–L *1 : w/ A/T Indicator Light *2 : w/o A/T Indicator Light *3 : S/D, C/P R–L L–R 2 IP3 R–L O (M/T) (A/T) P1 A/T INDICATOR SW [PARK/NEUTRAL POSITION SW] (NEUTRAL START SW) R–L R–L Y–L BACK–UP LIGHT [REAR COMB. LIGHT] 2 R9 A 2 B1 BACK–UP LIGHT SW (M/T) G–O 2 D N R P 4 3 10 9 8 7 R R–B G–W R–B (A/T) R 7 5 5 II1 3 Bd2 9 G–O (*1) B B L 2 D N 6 4 R 3 P 4 A (*3) 3 B (W/G) 4 A (*3) 3 B (W/G) BACK–UP LIGHT [REAR COMB. LIGHT] R9 LH R11 RH 4 A (*3) 4 A (*3) 3 B (W/G) 3 B (W/G) C11 A/T INDICATOR LIGHT [COMB. METER] W–B (*3) W–B (*1) W–B (W/G) W–B B Left kick panel R–B (W/G) W–B (W/G) W–B 3 POWER O/D OFF O5 O/D MAIN SW R–B R–B B–O (*1) 10 6 Bc2 G–W (*1) O (*1) 11 R–B (W/G) R–B (*1) Y–L (*1) 13 (*1) L–R (*1) 8 10 IJ1 R–B R–B (*3) 9 IQ1 W–B 1 IP3 W–B (*3) 13 IQ1 Back door center BR 4 Ba1 W–B 14 IQ1 R–L (*1) 1 IF B 1 2 3 4 R–B (*3) 8 IQ1 3 Ba1 R–B (*3) R–B (M/T) 7 IQ1 R–B O G–O G–O From Combination Meter<33–4> G–O (*1) J2 JUNCTION CONNECTOR , 1 IP3 Y–L II2 G–O From Data Link Connector 2 (TDCL)<4–6> R11 A 1 2 3 4 1 O O 2 B R–B (M/T) L Y–L Y–L G–O G–O D J1 JUNCTION CONNECTOR B–O D D , Under the left quarter pillar BL S top L ight (W /G ) P o w e r S o u rc e 1 Headlight (for USA) 3 2 4 W W B FUSE BOX ACC 3 1G 1 2E 2 2H 40A AM1 G–W HS BL 3 BQ DIMMER SW G–R 4 H T R R R–Y R–Y W–B H3 HEADLIGHT LO LH H1 HEADLIGHT HI LH R–B H4 HEADLIGHT LO RH W–B R–B ED HF HI R–B TAIL HEAD 8 ED1 LOW R–B HIGH FLASH NOISE FILTER 11 9 N2 A 2 Lower back panel center 2 12 OFF W–B 4 2 2 W–B 2 H10 HIGH MOUNT STOP LIGHT 2 1 N3 B W–B 1 R10 STOP LIGHT RH [REAR COMB. LIGHT RH] G–R 6 Bb1 R11 STOP LIGHT RH [REAR COMB. LIGHT RH] G–R G–R LIGHT CONTROL SW 1 5 Bd2 14 2 1 R–B C12 COMBINATION SW W–B W–B C G–R 13 2 1 W–B 1 14 1 BR Back door center IE Left kick panel 1 1 2 W–B 7 +STP H2 HEADLIGHT HI RH 4 4 Bd2 13 R–B R W–B W–B C C J5 JUNCTION CONNECTOR W–B 3 R8 STOP LIGHT LH [REAR COMB. LIGHT LH] G–R 1 BATTERY I13 INTEGRATION RELAY EL 4 Bc2 C9 HIGH BEAM INDICATOR LIGHT [COMB. METER] 5 Bc2 2 G–R R–Y R–B 3 1 R–B –TR B L2 LIGHT FAILURE SENSOR F16 C G–W 9 3C R 9 +TR –STP R–Y G–W 3 E R–B 17 1H R LG Y–G B 14 1L 5 ED1 4 11 8 (5S–FE) F10 B 1 15 1A 1 WRN Under the left quarter pillar 6 1M 2 To ABS ECU<25–4><26–4> To Cruise Control ECU<24–2> To Engine Control Module (Engine and Electronic Controlled Transmission ECU) <3–8><4–7> To Shift Lock ECU<23–2> FUSE BOX FL MAIN 2. 0L 6 2A 5 2A 2 B To Taillight [REAR COMB. LIGHT]<17–3> F16 C B B G–R 17 IJ1 F10 A , B , 1 C A , N3 G–R Y–G To License Plate Light <17–3> S10 STOP LIGHT SW W 3 1 A (1MZ–FE) 1 B (5S–FE) 100A ALT Y C9 REAR LIGHT WARNING LIGHT [COMB. METER] W 2 A 1 2A NOISE FILTER G W 3 2 2A N2 1 B 4 15A HEAD (LH) 1 R–B R–L 1 A 6 EF1 15A HEAD (RH) 7 2G W–B W 1 1E 2 G–R 6 1B 9 1H J1 JUNCTION CONNECTOR C R–L C 4 3 G–W 3 1M 1 EF1 HEADLIGHT RELAY I12 IGNITION SW 40A MAIN 15A STOP G–W 2 10A GAUGE R9 STOP LIGHT LH [REAR COMB. LIGHT LH] W B ST1 9 1G 2 2E 4 1E R–Y B–Y W–B IG1 2 R–Y 4 AM1 W (1MZ–FE) F10 A Front left fender EB OVERALL ELECTRICAL WIRING DIAGRAM 8 C AM R Y 9 CAM RY Turn Signal and Hazard Warning Light (S/D, C/P) S to p L ig h t (S /D , C /P ) P ow er S o urc e 1 3 2 4 B NOISE FILTER N3 B W N2 A ACC IG1 2 4 1E B–Y 2 15A STOP G–W W G–Y G–B 8 G–Y 5 Back panel center BO Under the left quarter pillar BL C12 TURN SIGNAL SW [COMB. SW] 5 2 LH RH W–B 23 1 ED1 W–B 18 3C 1 11 1C 2 1 1M W–B 5 1 1 6 3D G–Y G–Y 1 G–Y C8 TURN SIGNAL INDICATOR LIGHT [COMB. METER] G–Y G–Y G–B 11 BZ1 R10 REAR TURN SIGNAL LIGHT RH [REAR COMB. LIGHT RH] W–B G–Y 2 16 1H 10 BZ1 G–B G–B G–B 1 1A R8 REAR TURN SIGNAL LIGHT LH [REAR COMB. LIGHT LH] W–B G–B 4 ED1 1 W–B B 9 IJ1 F 5 1M B G–B F 8 1C W–B J1 JUNCTION CONNECTOR G–B 1 3 RH L G–W G–R W–B 2 2 W–B G–R G–R 2 1 TURN SIGNAL FLASHER W–B W–B 3 6 G–Y LH TR W–B 7 BZ1 4 Ba1 2 1 3 F7 FRONT TURN SIGNAL LIGHT LH W–B G–B HS R10 STOP LIGHT RH [REAR COMB. LIGHT RH] 5 W–B 1 TB 5 1 W–B +STP G–R W–B 2 W–B W–B 1 Ba1 R9 STOP LIGHT LH [REAR COMB. LIGHT LH] G–R G–R W–B 5 R10 STOP LIGHT LH [REAR COMB. LIGHT LH] G–R 2 9 BZ1 TL 1 W–B G–W G–W 1 2 W–B W–B R8 STOP LIGHT RH [REAR COMB. LIGHT RH] BATTERY 7 J1 JUNCTION CONNECTOR B L2 LIGHT FAILURE SENSOR G–R B2 R R (w/o Rear Spoiler) –TR 8 BZ1 4 BZ1 H10 HIGH MOUNT STOP LIGHT +TR 1 2 W–B WRN 5 Ba1 G–W (w/ Rear Spoiler) 8 G–W H10 HIGH MOUNT STOP LIGHT Y 9 –STP F 1 G–W 9 17 1H R LG G Y–G To ABS ECU<25–4><26–4> To Cruise Control ECU<24–2> To Engine Control Module (Engine and Electronic Controlled Transmission ECU) <3–8><4–7> To Shift Lock ECU<23–2> 3 E 14 1L G–W Y G–W 9 3C 4 11 8 7 1 1 C FL MAIN 2. 0L 10 ON 15 1A F16 C 1 G–W G–R Y–G 2 BZ1 2 2F OFF 6 1M B 3 BZ1 2 1A B1 To Taillight [REAR COMB. LIGHT]<16–3> F16 C FUSE BOX H7 HAZARD SW 2 S10 STOP LIGHT SW W Y–G To License Plate Light <16–3> 17 IJ1 B G–W W W C9 REAR LIGHT WARNING LIGHT [COMB. METER] F10 A , B , A , N3 2 B 1 B 3 1 A (1MZ–FE) 1 B (5S–FE) N2 2 A NOISE FILTER 6 3 EF1 FUSE BOX (1MZ–FE) F10 A G–R 1 A R–L J1 JUNCTION CONNECTOR C R–L C 1 W 2 (5S–FE) F10 B 3 1M 6 1B 9 1H 1 1E 10A HAZ 7. 5A TURN FUSE BOX 40A AM1 100A ALT 1 F8 FRONT TURN SIGNAL LIGHT RH W–B G–Y I12 IGNITION SW 2 B 1 G–B 10A GAUGE 9 1G 4 EF1 2 2H ST1 W W B 4 AM1 3 1G Left kick panel IE Front left fender EB Back panel center BO EA Front right fender IG Instrument panel brace LH H ead lig ht (fo r C an ada) 2 2E FUSE BOX 5 2A W 17 3A 11 3B 2 EB1 18 3A 9 3A R 7 (5S–FE) F10 B 8 ED1 5 3 2 2 1 R–B 4 R–B HRLY F16 C 3 7 7 7 1 4 3 EF1 1 From Generator (Alternator) <2–4> 1 1M To Parking Brake SW<33–3> To Brake Fluid Level SW<33–3> 9 11 R–G 2 14 7 1 4 W–B 2 1 7 3 7 R–B HEAD 13 DAYTIME RUNNING LIGHT RELAY NO. 4 TAIL 1 H2 HEADLIGHT HI RH OFF H1 HEADLIGHT HI LH HIGH 2 W–B 7 EL 4 EB1 5 EB1 R–B W–B W–B 11 1C R–Y H LOW C12 COMBINATION SW R–W T R–B A HL HU ED W–B 8 A 18 3C HF FLASH R–B HI W–B W–B J1 JUNCTION CONNECTOR H PKB 2 W–B 5 ED1 R–G R–Y 13 W–B R–Y 12 C9 HIGH BEAM INDICATOR LIGHT[COMB. METER] R–B 14 W–B 12 3A W–B 16 R–W 18 R–Y W–B BRK D4 DAYTIME RUNNING LIGHT RELAY (MAIN) 11 5 DRL CHG– Y B 13 +B 17 DIMMER LIGHT CONTROL SW SW IG E R–Y 15 R–B 2 1 C 1 W–B 3 EB1 R F16 C FUSE BOX BATTERY 5 R–G F10 A , B FL MAIN 2. 0L W–B L–Y R–L R–B W–R R–G 2 W–B W 100A ALT 1 A (*1) 1 B (*2) 4 5 7 1 H I13 INTEGRATION RELAY 15A HEAD (LWR–RH) 7 2 2A R–L R–B (1MZ–FE) F10 A W W 1 5 R 1 1E B 2 5 15A HEAD (LWR–LH) 7. 5A DRL FUSE BOX 1 B L–Y 40A AM1 3 2G R–L I12 IGNITION SW 3 15A HEAD (UPR–RH) 3 R–W 7 1B R–B 2 1 7 2G 1 2E 15A HEAD (UPR–LH) 5 1 R 3 ST2 9 1G DAYTIME RUNNING LIGHT RELAY NO. 2 HEADLIGHT RELAY 40A MAIN 5 2 DAYTIME RUNNING LIGHT RELAY NO. 3 IG2 15A ECU–B 1 W–R 10A GAUGE 2 R W AM2 7 5 4 H3 HEADLIGHT LO LH 2 2H 3 1G R IG1 2 ST1 4 W 1 EB1 W B B B–Y ACC 4 AM1 W W 3 6 EC1 B W 2 R–L 1 *1 : 1MZ–FE *2 : 5S–FE H4 HEADLIGHT LO RH P ow e r S ou rce W–B IG Instrument panel brace LH IE Left kick panel Front left fender EB OVERALL ELECTRICAL WIRING DIAGRAM 10 CAMRY IG Instrument panel brace LH Left kick panel IE 1 1 1K 1 2 7 1K 15 1K 9 1K INTEGRATION RELAY 3 1 DIODE 2 R–Y 1 16 IU1 1 2 D7 DIODE (for Courtesy) 6 IU1 BATTERY R–W 15 II2 R–G 1 17 IJ1 6 II2 2 2 II2 R–W Left kick panel B 1 1 IF L3 LUGGAGE COMPARTMENT LIGHT (w/ Moon Roof) R R R D16 DOOR KEY CYLINDER LIGHT AND SW R R Interior Light (S/D, C/P w/ Key Illuminated Entry) LH BK RH 4 2 1H 5 BZ1 B Roof left M3 PERSONAL LIGHT R–B G–R From Door Lock Control Relay<19–3> R–B 16 IH2 W–B 19 1H 9 IH1 G–R R–Y (*2) R C9 OPEN DOOR WARNING LIGHT[COMB. METER] R V9 VANITY LIGHT RH R R 3 L4 LUGGAGE COMPARTMENT LIGHT SW 3 1B 11 IH1 W–B 8 II2 2 R–W(S/D) R–Y(C/P) 5 1M 2 1B 4 W–B 1 1M 5 J1 JUNCTION CONNECTOR W–B (*2) 1 From Door Lock Control Relay <19–3> 6 1I 15 IJ1 3 R–W 6 IV2 2 R (*2) W–B (*1, S/D) 1 R–Y (*1, S/D) 2 I11 IGNITION KEY CYLINDER LIGHT W–B 4 R–W 4 IV2 G–R W–B 2 16 3A R–B 4 1I 14 3D R–W 6 (*2) 1 14 3C R–W 4 V8 VANITY LIGHT LH R 1 D13 DOOR COURTESY SW FRONT RH R–G 1 1 G–R 5 1C OFF ON 2 D12 DOOR COURTESY SW FRONT LH R–G R–Y 10 12 1K 2 (S/D) FL MAIN 2. 0L R–Y R–L (*2) 6 1H DOOR R 1 D15 DOOR COURTESY SW REAR RH R–Y (S/D) R–W (S/D) 1 1I I14 INTERIOR LIGHT 3 II2 R–W (*2) 1 IV2 R–W (*1, S/D) A R A J3 JUNCTION CONNECTOR Power S o u rc e D14 DOOR COURTESY SW REAR LH 1 1C R R (*2) 2 2H R R R (*1, S/D) 2 2G W–B R–W (*2) R (*2) R B 20A DOME W–B B 11 CAM RY *1 : TMC Made *2 : TMM Made B R 4 R 10 IH1 W–B 1 P ow er S o u rc e Interior Light (W/G w/ Key Illuminated Entry) *1 : LE and GL Grade in Canada 1 3 2 4 B 10 IH1 R R B R R (*1) 1 M3 PERSONAL LIGHT 6 II2 2 DIODE 2 II2 R–W R–Y W–B W–B R–W D7 DIODE (for Courtesy) 1 2 B R–W R–W R–Y R–W D9 DIODE (for Courtesy) 2 1H R–G 1 1K 4 2 R–Y 19 1H 1 2 RH B 6 IV1 J2 JUNCTION CONNECTOR W–B 1 1 1M R–W R–Y 2 3 4 W–B B R–W 9 1K 10 R–W LH W–B (*1) R–W R–W 3 INTEGRATION RELAY 2 Bc3 2 Bd2 From Door Lock Control Relay <19–3> 2 2 FL MAIN 2. 0L 1 Back door center BR Instrument panel brace LH IG 1 W–B W–B 6 1I 1 5 1M W–B 1 D13 DOOR COURTESY SW FRONT RH R–W 1 6 IU1 D12 DOOR COURTESY SW FRONT LH R–G W–B W–B 1 16 IU1 D15 DOOR COURTESY SW REAR RH R–Y L4 LUGGAGE COMPARTMENT LIGHT SW D14 DOOR COURTESY SW REAR LH R–W 2 BATTERY W–B (*1) 15 1K 1 V9 VANITY LIGHT RH 7 1K R–G 4 1I R (*1) R–B 15 II2 R–W G–R 8 II2 G–R R–W 4 IV1 16 IH2 V8 VANITY LIGHT LH From Door Control Relay <19–3> R–B 9 IH1 11 IH1 R (*1) R (w/ Moon Roof) 2 R W–B W–B 4 G–R OFF ON DOOR R 2 1B L3 LUGGAGE COMPARTMENT LIGHT 1 1 2 15 IJ1 1 3 R–W 5 1C 6 1H 5 1 G–R R–W R 1 1I 4 R–Y R R R R 12 1K I11 IGNITION KEY CYLINDER LIGHT R C9 OPEN DOOR WARNING LIGHT[COMB. METER] 1 Bc2 A I14 INTERIOR LIGHT 2 3 II2 1 1C 14 3D A R J3 JUNCTION CONNECTOR 16 3A 2 2G R R R R 20A DOME R 1 IV1 14 3C D16 DOOR KEY CYLINDER LIGHT AND SW 2 2H Left kick panel IF BP Roof right Left kick panel IE OVERALL ELECTRICAL WIRING DIAGRAM 12 CAMRY 13 CAMRY Power Source *1 : *2 : *3 : *4 : Interior Light (S/D, C/P w/o Key Illuminated Entry) 1 3 2 TMC Made TMM Made w/ ABS w/o ABS 4 B 2 2H 20A DOME R 2 2G 1 1C 6 1H 5 1C R (*1, S/D) 14 3C R R (*2) R 1 IV2 R (*1, S/D) R 14 3D C9 OPEN DOOR WARNING LIGHT[COMB. METER] FL MAIN 2. 0L 3 1I R–G R–Y (*2) 7 IJ1 R–L (*2) 3 1B 6 II2 I11 IGNITION KEY CYLINDER LIGHT 2 L3 LUGGAGE COMPARTMENT LIGHT 2 1B 2 6 1K DIODE 1 2 R–W 3 IV2 5 IJ1 R (*2) R–Y (*1, S/D) R–W (*2) 5 R–W (*2) 4 R–W (*1, S/D) B RH 1 1 1 LH R R 4 G–R DOOR M3 PERSONAL LIGHT 16 3A R–W 2 1 From Door Control Relay<19–3> R (*2) (*2) OFF ON I14 INTERIOR LIGHT R (*1, S/D) R (*2) 1 1I INTEGRATION RELAY 2 5 BZ1 From Door Lock Control Relay <19–3> 6 IU1 16 IU1 R–Y (*3, S/D) 1 IG Instrument panel brace LH R–W 1 D15 DOOR COURTESY SW REAR RH R–W(S/D) R–Y(C/P) R–W R–W (*3) R–G 1 W–B 1 R–Y (*3, S/D) R–Y R–W (*4) D7 DIODE (for Courtesy) 1 2 1 1M D12 DOOR COURTESY SW FRONT LH 1 2 II2 R–G R–W (*4) D13 DOOR COURTESY SW FRONT RH R–W R–W (S/D) R–Y D15 DOOR COURTESY SW REAR RH R–W (S/D) BK D14 DOOR COURTESY SW REAR LH Roof left 1 2 1H R–G 1 1K From Door Lock Control Relay <19–3> 19 1H (S/D) BATTERY From Door Lock Control Relay <19–3> W–B 10 1 D13 DOOR COURTESY SW FRONT RH L4 LUGGAGE COMPARTMENT LIGHT SW BP Roof right 1 FL MAIN 2. 0L 1 R–W 1 1 1K 2 II1 1 2 1 6 IU1 R–W R–W 6 II2 5 I11 IGNITION KEY CYLINDER LIGHT 1 3 D9 DIODE (for Courtesy) 2 1H 2 16 IU1 R–W 1 Instrument panel brace LH IG R R R–W 14 3D 1 2 L3 LUGGAGE COMPARTMENT LIGHT 16 3A R–W G–R R–Y C9 OPEN DOOR WARNING LIGHT[COMB. METER] From Door Lock Control Relay<19–3> 4 R–Y R–W 9 1K R–W From Door Lock Control Relay<19–3> R R R 3 L4 LUGGAGE COMPARTMENT LIGHT SW DIODE R–W 3 1I R–W 3 IV1 W–B BATTERY I14 INTERIOR LIGHT W–B R–W 19 1H R–G 2 D13 DOOR COURTESY SW FRONT RH 4 OFF ON 2 D7 DIODE (for Courtesy) M3 PERSONAL LIGHT R–W 1 R–G R–Y 1 1I D12 DOOR COURTESY SW FRONT LH R–G R–Y 1 IV1 DOOR R (w/ Moon Roof) 20A DOME D15 DOOR COURTESY SW REAR RH R–Y 1 R–W 5 1C R R R B B 1 R–W 6 1H R–W 1 1C R R 2 2G D14 DOOR COURTESY SW REAR LH W–B B P ow er S o u rc e Interior Light (W/G w/o Key Illuminated Entry) 4 2 2H 14 3C 1 Bc2 15 IJ1 2 Back door center 1 2 R–W 2 Bc3 2 2 1B 2 Bd2 INTEGRATION RELAY 1 1H 10 R–Y 2 1 BR OVERALL ELECTRICAL WIRING DIAGRAM 14 CAM RY 15 C AM RY Power Source *1 : *2 : *3 : *4 : Illumina tion 1 Push Control SW Type A/C Lever Control SW Type A/C w/ CD Player w/o CD Player 3 2 4 COMBINATION METER W BLOWER SW C9 B C 8 A BLUE B6 A , 4 1E 1 2 3 4 5 6 5 TAILLIGHT RELAY (*1) H 8 A BLACK 7 1L 4 1B G 12345 G G G B 12 II2 B R 3 B BLUE 1 2 4 2 5 6 3 7 3 4 5 6 7 8 9 10 1 R 4 C BLUE 1 G G–W G3 GLOVE BOX LIGHT G 4 2 1 2 1 3 2 1 IN1 C C C C C B B F16 C 1 (A/T) G B RADIO AND PLAYER 1 1 2 5 IM1 1 R 2 A BLUE 2 G4 GLOVE BOX LIGHT SW 8 1L 1 B 1 1D B 2 2 IN1 B (A/T) 1 3D (5S–FE) F10 B BATTERY A B (A/T) 5 1B A B (A/T) 2 1D B (*3) 11 3D A E6 ELECTRONIC CONTROLLED TRANSMISSION PATTERN SELECT SW G B B B 9 A (*3) 5 C (*4) B (*4) 11 3C A 2 A (*3) 10 B (*4) RADIO AND PLAYER B B G (*3) G (*4) 3 B (*2) B FL MAIN 2. 0L J2 JUNCTION CONNECTOR A O5 A/T INDICATOR LIGHT (Shift Lever) To Clock <22–3> FUSE BOX 7 8 17 18 15 A (*1) B 1 C 10 IM2 (A/T) B (1MZ–FE) F10 A 5 6 11 12 13 14 15 16 G G (*3) 7 B (*2) G 14 A (*1) 4 B (*2) W–G (*3) C11 A/T INDICATOR LIGHT [COMB. METER] 8 A (*1) A HEATER CONTROL SW 6 B (*2) A12 B A/C SW A , B 13 A BLOWER SW 16 B B6 B A , C9 COMBINATION METER 4 C8 G R5 REAR WINDOW DEFOGGER SW G 1 5 B 2 2 6 A (*1) 3 4 9 10 16 II2 H8 G G G G G 1 C5 CIGARETTE LIGHTER ILLUMINATION A18 ASHTRAY ILLUMINATION B H7 HAZARD SW 3 B 100A ALT 2 FUSE BOX F10 A , B , F16 C G 4 3C 1 2 W–B 11 1D J2 JUNCTION CONNECTOR B 2 3 4 5 6 Left kick panel IF J2 JUNCTION CONNECTOR 21 3D HEATER CONTROL SW W–B 21 3C A/C SW (*2) A12 B BLACK W–B 20 3C G 5 3D 1 A (1MZ–FE) 1 B (5S–FE) 6 7 8 G 9 3D 10 1D R7 RHEOSTAT 20 3D G 14 1D G To Integration Relay <34–2> W 4 EF1 2 3 5 G G W 1 3 G–R 8 1B 9 10 11 12 13 14 15 16 4 15A TAIL 2 1 2 3 4 5 6 7 8 7 8 9 10 11 12 13 (A/T) 1 B BLACK Power Source T a illig h t (S/D, C/P) 1 3 2 4 FUSE BOX W (1MZ–FE) F10 A (5S–FE) F10 B F16 C 4 1E 1 5 TAILLIGHT RELAY 1 15A TAIL 3 W 2 14 1D G G 5 3D 12 BZ1 To Diode(for Idle–Up) <3–8><4–6><5–4> From Light Failure Sensor<9–1> LG LG 13 BZ1 LG I13 INTEGRATION RELAY F10 A , B , F16 C FUSE BOX 2 Ba1 1 4 LG 6 TAILLIGHT LH W–B 5 R8 [REAR COMB. LIGHT LH] W–B W–B W–B 4 Ba1 W–B W–B W–B Left kick panel IE Front left fender EB 3 W–B W–B R10 [REAR COMB. LIGHT RH] REAR SIDE MARKER LH TAILLIGHT RH 5 7 BZ1 W–B 4 W–B W–B REAR SIDE MARKER RH 1 W–B 2 L1 LICENSE PLATE LIGHT 2 W–B BATTERY 2 W–B W–B 11 2 2 EA Front right fender BL Under the left quarter pillar BO Back panel center W–B 1 3 R9 TAILLIGHT LH [REAR COMB. LIGHT LH] 6 1 F6 FRONT SIDE MARKER RH HEAD 1 W–B TAIL 1 F4 FRONT CLEARANCE LIGHT RH OFF H W–B EL LG R11 TAILLIGHT RH [REAR COMB. LIGHT RH] 1 G LG 1 G G G G G G G G 2 T LIGHT CONTROL G F5 FRONT SIDE MARKER LH C12 COMBINATION SW F3 FRONT CLEARANCE LIGHT LH B G 1 C FL MAIN 2. 0L G 3 ED1 LG 2 W–B 100A ALT 1 A (1MZ–FE) 1 B (5S–FE) G G 4 3D LG G–R 4 EF1 From Light Failure Sensor<9–1> 7 1H G 8 1B W 1 OVERALL ELECTRICAL WIRING DIAGRAM 1 6 C AM R Y 17 CAM RY Power S o u rc e T a illig h t ( W / G ) 1 3 2 4 FUSE BOX W (1MZ–FE) F10 A (5S–FE) F10 B F16 C 4 1E 1 5 TAILLIGHT RELAY 1 1 15A TAIL 3 W 14 1D G G G 5 3D G–R 4 EF1 From Light Failure Sensor<8–1> LG To Diode(for Idle–Up) <3–8><4–6><5–4> 4 3D W From Light Failure Sensor<8–1> 7 1H LG 2 8 1B LG G F16 C FUSE BOX 7 Bb1 LG LG LG 2 Bc2 3 ED1 I13 INTEGRATION RELAY F10 A , B , 6 Bd2 1 G LG G G G 1 C G 1 LG 4 W–B 1 4 R9 TAILLIGHT LH [REAR COMB. LIGHT LH] 3 R8 TAILLIGHT LH [REAR COMB. LIGHT LH] W–B 3 R10 TAILLIGHT RH [REAR COMB. LIGHT RH] R11 TAILLIGHT RH [REAR COMB. LIGHT RH] 1 W–B W–B 1 W–B 2 L1 LICENSE PLATE LIGHT F6 FRONT SIDE MARKER RH 2 2 W–B BATTERY 2 2 2 W–B W–B 11 2 1 W–B G G G HEAD 1 F4 FRONT CLEARANCE LIGHT RH TAIL H W–B EL OFF W–B W–B C Left kick panel IE Front left fender EB EA J5 JUNCTION CONNECTOR W–B W–B C W–B LIGHT CONTROL T FL MAIN 2. 0L 1 2 F5 FRONT SIDE MARKER LH C12 COMBINATION SW F3 FRONT CLEARANCE LIGHT LH B 1 Bd2 LG G 100A ALT 2 G G 3 Bc2 1 A (1MZ–FE) 1 B (5S–FE) Front right fender BQ Lower back panel center BL Under the left quarter pillar BR Back door center OVERALL ELECTRICAL WIRING DIAGRAM 18 CAM RY P ower S ource Turn Signal and Hazard Warning Light (W/G) F ro n t W ip e r a n d W a s h e r 1 Horn 3 2 4 B FUSE BOX ACC IG1 2 (5S–FE) F10 B B–Y F16 C ST1 1 20A WIPER ST2 W OFF OFF MIST ON TL TB TR 5 6 RH B2 5 8 1 5 2G B 16 1H 2 IJ1 4 Bb1 4 4 Front right fender EA Left kick panel W–B IE Front left fender EB Under the left quarter pillar BQ Lower back panel center EA G–W HORN G–Y 11 1C 1 1M Front right fender IG Instrument panel brace LH 1 H6 RH (1MZ–FE) F10 A W–B 2 C BL 1 H5 LH W–B F9 FRONT WIPER MOTOR 10 FUSE BOX 18 3C W–B W–R 1 C J5 JUNCTION CONNECTOR 3 3 1 W–B W–B 5 1M 3 RH 6 3D F8 FRONT TURN SIGNAL LIGHT RH G–Y M R10 REAR TURN SIGNAL LIGHT RH [REAR COMB. LIGHT RH] 8 1C 2 L 6 1 ED1 W–B W–B L–O 2 1 W–B 3 F R8 REAR TURN SIGNAL LIGHT LH [REAR COMB. LIGHT LH] 5 L–B L–Y FL MAIN 2. 0L J1 4 ED1 JUNCTION CONNECTOR F7 FRONT TURN SIGNAL LIGHT LH G–B 16 IR1 W–B 15 IR1 G–B LH F 14 IR1 2 C12 HORN SW [COMB. SW] J1 JUNCTION CONNECTOR 1 W–B W–B B B G–B 1 1 C 3 2A G–B G–Y G–Y TURN SIGNAL FLASHER C8 TURN SIGNAL INDICATOR LIGHT [COMB. METER] 3 FUSE BOX 4 1A G–Y L–W L–W G–Y 16 1 1 G–B 8 W–B 13 L–B L–Y 7 L–O 4 11 IR1 F10 A , B , 2 3 G–B L–W 1 WIPER RELAY 1 A (1MZ–FE) 1 B (5S–FE) BATTERY HORN RELAY C12 TURN SIGNAL SW [COMB. SW] LOW WASHER F16 C F 7 HIGH W B1 LH E INT 3 EF1 100A ALT W 1 G–B W W1 M WASHER MOTOR 1 +2 9 G–W 2 +1 8 G–W 1 1E +S 2 10 G–Y B H7 HAZARD SW G–W G–W 18 G–R 1 2 2F C13 FRONT WIPER AND WASHER SW [COMB. SW] L L G–W L L L L I12 IGNITION SW 17 IR1 L 40A AM1 15A HORN 2 1A 2 1M 2 G–B 9 1G B 10A HAZ IG2 G–Y AM2 1 7. 5A TURN G–B 4 AM1 W 2 2H 3 1G 19 CAMRY Power Source 3 2 D20 B , D21 B 10A GAUGE 1 12 9 13 6 4 3 L–W L LG–R L–R L–R L–B LG G L–W 4 IH2 L–R L–B Y L–R L–B 19 IH2 6 IT1 11 IT1 16 IT1 L–R(W/G) IG W–B W–B J2 JUNCTION CONNECTOR B B 2 A (*1) 5 B (*2) 4 M 2 1 2 3 4 D19 B IF 12345 L–R L–B 4 Bc1 3 Bd1 L–B (*1) 1 Bd1 M 2 DOOR LOCK CONTROL SW LH 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Left kick panel 2 Bc1 L–B (*1) L–R (*1) 4 D28 B , C B W–B D19 A Instrument panel brace LH 8 BY1 19 IT1 W–B P12 A DOOR LOCK CONTROL SW RH 3 BY1 L–B 4 B 8 BW1 12345 16 IG1 L–B 1 A L–B (*1) L–R (*1) 3 BW1 M 6 IG1 L–R W–B 4 B (*1) 15 IU1 L–R 2 A (*1) 5 B (*2) 7 A (*2) 3 B 5 IU1 B9 BACK DOOR LOCK MOTOR 4 B 6 A 15 IG1 L–B (*1) D23 DOOR LOCK MOTOR REAR RH L–R (*1) 1 A 5 IG1 L–B D22 DOOR LOCK MOTOR REAR LH L–R (*1) M W–B 16 IH2 W–B W–B IJ L–B(W/G) L–R Y 7 A (*1) DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT RH 4 B (*2) 6 A L–B 3 B D21 B , D27 A D20 B , D26 A 2 L–R L–R LG–R UNLOCK 1 W–B W–B 3 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH 2 9 IH2 1 1M Right kick panel L–B(*1) L–R(*1) W–B W–B 1 2 IT1 W–B 6 C (*2, *3) 3 1 IT1 L UNLOCK D18 DOOR KEY LOCK AND UNLOCK SW RH L–W LOCK 4 A (*3) 3 B (*4) 3 IH2 W–B 2 A (*3) D17 DOOR KEY LOCK AND UNLOCK SW LH L–W LOCK G 1 B (*4) 3 A UNLOCK UNLOCK 2 A (*1, *3) 3 B (*4) 5 B LOCK 3 A (*1, *3) D19 A , B 4 A DOOR LOCK CONTROL SW RH 1 C (*2, *3) 1 B (*4) 5 4 1G LG G LG 5 B LOCK P12 A , B , C I12 UNLOCK WARNING SW [IGNITION SW] W–B R–L 1 BATTERY 14 IH2 L–B L–R L–R (*1) G 12 IT1 L–W LG 5 IT1 DOOR LOCK CONTROL SW LH 100A ALT 2 1G FL MAIN 2. 0L 5 R–L From Integration Relay<34–2> W W 13 IH2 2 C 1 C LSWP L–R 10 IH2 1 Y LSWD L–B ACT– 11 14 1K B C FUSE BOX F10 A , B , F16 R–G ACT+ 10 19 II2 1 A (1MZ–FE) 1 B (5S–FE) F16 C 1 7 4 EF1 3 EF1 W (5S–FE) F10 B DSWD D8 DOOR LOCK CONTROL RELAY L2 UL3 UL2 UL1 5 7 2 DSWP G W–B L1 14 RLY 2 4 6 LG KSW 16 R–L 15 +B 3 R–L E W W 1 1E 5 II2 8 IG R–W L–R 1 1 4 1 10 II2 40A AM1 R–L R–L 4 II2 W–L J3 JUNCTION CONNECTOR C R–L C 8 1K I12 IGNITION SW 2 2 3 D26 A , D27 A GRAY 2 1K 9 1G 1 L–B (*1) IG2 ST2 W–L AM2 30A POWER FUSE BOX (1MZ–FE) F10 A L–R (*1) ST1 To Door Courtesy SW Front RH <11–4><12–4><13–2> <13–4><14–3> 2 3 1G To Door Courtesy SW Front LH <11–3><12–3><13–2> <14–3> 2 1E To Power Main Relay <20–2> B–Y IG1 2 W ACC 4 AM1 S/D, W/G C/P w/ Power Window w/o Power Window 4 DOOR LOCK MOTOR AND DOOR UNLOCK DETECTION SW FRONT LH, RH L–B (*1) 1 W W *1 : *2 : *3 : *4 : Door Lock 4 M 2 Pow er Source Remote Control Mirror 1 F16 C L–R I12 IGNITION SW 40A AM1 From Door Lock Control Relay<19–2> W 9 1G FUSE BOX 1 2 11 1K 17 II2 L 5 1I 3 L C V2 H2 6 IH2 L L L P12 A , B (*3) 8 A (*4) 9 B B L To Moon Roof Control Relay <21–2> 10 1K 8 V1 3 4 1 2 5 6 7 8 9 10 L(*1) L(*2) L W H1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 5 POWER MAIN RELAY 1 1M R6 REMOTE CONTROL MIRROR SW E P12 B P12 A 3 2 1 L 1 1E POWER WINDOW MASTER SW (*1) R20 B , R21 B 1 1 J3 JUNCTION CONNECTOR B L–R L–R B 9 II2 REMOTE CONTROL MIRROR LH, RH (*2) R20 A , R21 A 30A POWER 1 (*5) F10 A 4 1 2 3 IG2 9 1L *4 : S/D, W/G *5 : 1MZ–FE *6 : 5S–FE 2 1 ST2 W 2 1E (*6) F10 B 15A CIG/RADIO 2 W FUSE BOX ST1 AM2 R–L 10 1G IG1 6 1L R–L P–L 4 AM1 3 2 ACC 3 *1 : TMC Made *2 : TMM Made *3 : C/P Power Window 7 A POWER WINDOW MASTER SW Left kick panel IF R20 A , B R21 A , B REMOTE CONTROL MIRROR LH REMOTE CONTROL MIRROR RH Instrument panel brace LH IG Left kick panel IF (*4) (*3) 1 2 1 2 M P13 POWER WINDOW MOTOR FRONT LH 1 DOWN UP DOWN 1 M 2 4 P14 POWER WINDOW MOTOR FRONT RH 2 M 1 R–Y G–Y 1 L 6 BW1 5 BW1 P16 POWER WINDOW MOTOR REAR RH 2 3 L 7 BW1 R–B(S/D) R–Y(W/G) L R–Y 13 IG1 R–Y G–Y 12 IG1 G–Y R–B 4 4 IG1 5 1 4 2 M DOWN P10 POWER WINDOW CONTROL SW REAR LH B 2 IH2 R M G M R M W–B M W–B W–B B J2 JUNCTION CONNECTOR R–B 3 B 3 R 2 B G–B 2 B G–B 3 B UP 1 B 3 A (*1) 1 B (*2) R (*4) 1 A (*3) 2 A P9 POWER WINDOW CONTROL SW FRONT RH LG–B 2 A G LG–R 1 A W–B LG–R 3 A 2 5 5 7 IH2 G–B 3 6 BY1 UP LG BR–Y B BR–W J2 JUNCTION CONNECTOR BATTERY B 7 BY1 G 8 IT2 12 IU1 5 BY1 R (*3) 6 IT2 L 7 IT2 4 IU1 L R 5 IH1 13 IU1 9 A (*4) (*3) 10 A DOWN P11 POWER WINDOW CONTROL SW REAR RH UP G L 2 W–B LG 6 IH1 R–B 4 IT1 12 IH2 R–B 10 IT1 11 IH2 L 16 IH2 4 IH1 UP 9 IT1 G–B 1 IH2 L 14 A G–B R–L 5 IH2 R–L 7 R–L 3 11 A G–W 5 LG–B LG–R BR–Y FL MAIN 2. 0L BR–W W–B B 1 C 7 B G–W 6 4 B 5 A 10 B G–W 1 13 A 3 B LG–R 2 6 A 6 B W–B FUSE BOX W–B LEFT F16 C 2 A 12 A L 1 A RIGHT B , G DOWN LH F10 A , LG–R 100A ALT 1 A (*5) 1 B (*6) DOWN W LOCK SW UP G (*4) POWER WINDOW RELAY L LEFT UP RIGHT W UP RH DOWN 18 II2 DOWN 3 EF1 W 4 EF1 DOWN UP 1 P15 POWER WINDOW MOTOR REAR LH OVERALL ELECTRICAL WIRING DIAGRAM 20 C AM R Y 21 CAM RY P ower S o urc e Moon Roof 1 Power Seat *1 : TMC Made *2 : TMM Made 3 2 4 W B FUSE BOX 2 2H 2 1E (1MZ–FE) F10 A 2 20A DOME (5S–FE) F10 B F16 C 1 30A POWER 1 1 R–W 20 1H R W 2 2G 1 1C 4 IO1 From Power Main Relay<20–3> R–W 4 EF1 L (*2) B 5 IV1 (W/G) 5 IV2 (S/D, C/P) M M5 MOON ROOF MOTOR 4 2 R–G (EX. C/P) R–B (EX. C/P) REAR RECLINING 7 R FRONT 4 L–Y DOWN 6 L–W UP 2 2 1 1 2 1 2 2 1 P8 POWER SEAT MOTOR (for Slide Control) C J5 JUNCTION CONNCTOR W–B (W/G) W–B REAR 11 M C Roof left(S/D) Roof right(W/G, C/P) SLIDE FRONT 12 5 IO1 W–B BP : S/D BK : W/G, C/P 8 L–R R 3 5 MTR+ W–B (W/G) G 1 2 MTR– W–B R–W TILT DOWN 4 R–L R–Y TILT UP 4 5 1 W–B M3 MOON ROOF CONTROL SW 2 LS2 9 NO. 2 G–Y CLOSE 5 LS1 8 W–B P 6 E 11 G–W 7 3 DOWN NO. 1 3 W–B UP 2 M4 MOON ROOF LIMIT SW CLS 1 OPEN BATTERY OPN B2 L–B 6 B L 12 W–B(S/D, C/P) B M2 MOON ROOF CONTROL RELAY W–B L (*2) FUSE BOX 1 C FRONT VERTICAL 9 R (*2) (S/D, C/P) DOWN (W/G) REAR VERTICAL 1 IV1 1 IV2 L (*1) F10 A , B , F16 C FL MAIN 2. 0L P4 POWER SEAT CONTROL SW 10 R (*2) R (*1) 100A ALT 1 A (1MZ–FE) 1 B (5S–FE) UP W 1 1I BL Under the left quarter pillar M P5 POWER SEAT MOTOR (for Front Vertical Control) M P6 POWER SEAT MOTOR (for Rear Vertical Control) M P7 POWER SEAT MOTOR (for Reclining Motor Control) Power Source Rear Wiper and Washer 1 3 2 B W B–Y P–L IG1 2 B–Y 4 AM1 4 FUSE BOX P–L ACC 3 Back Door Lock (W/G w/o Power Window) Cigarette Lighter and Clock 3 1G 10 1G 2 2H 2 1E (1MZ–FE) F10 A B W ST1 AM2 20A WIPER IG2 15A CIG/RADIO 20A DOME 30A POWER ST2 9 1G 40A AM1 7 1D 2 1M 17 IR1 L 2 2G 2 1K 15 1H L W–L W1 WASHER MOTOR 3 2 L–O M I12 IGNITION SW L–R 18 IR1 10 II2 W 4 EF1 3 EF1 OFF W INT E L R L–R L L–O L C 6 W 2 C4 CIGARETTE LIGHTER L 4 3 C6 CLOCK 1 1 W B3 BACK DOOR LOCK CONTROL SW 2 LOCK W C13 REAR WIPER AND WASHER SW [COMB. SW] L–R 1 1 1E UNLOCK 2 2 5 L L–W L–Y L–Y L L–W 6 3 8 4 1 2 8 Bd1 6 Bd1 7 Bd1 (5S–FE) F10 B 1 1 4 L–B W–B L–R L–R L–B 1 Bd3 3 Bd3 5 1M F16 C W–B W–B W–B W–B Under the left quarter pillar 1 B9 BACK DOOR LOCK MOTOR M J5 JUNCTION CONNECTOR R18 REAR WIPER MOTOR M 1 2 W–B W–B C BL 4 Bc1 2 3 C 2 Bc1 L–R 7 Left kick panel G W–B From ” TAIL” Fuse <15–2> FUSE BOX 8 1C L–Y R19 REAR WIPER RELAY IE 16 IG1 L–B 4 IJ1 BATTERY 6 IG1 L–B 8 IJ1 J2 JUNCTION CONNECTOR L–R 14 IJ1 L–O 7 Bc3 P–G 8 Bc3 P–B B FL MAIN 2. 0L W–B L–W 6 Bc3 1 C F W–B FUSE BOX 3 F L–W F16 C 1 10 L F10 A , B , P–B(USA) P–G(Canada) W–B 1 P–G 16 L WASHER 1 A (1MZ–FE) 1 B (5S–FE) 100A ALT L–O W ON BR Back door center IE Left kick panel Right kick panel IJ OVERALL ELECTRICAL WIRING DIAGRAM 22 CAM RY 23 CAM RY 4 4 1L B W 1 2 FUSE BOX G–W L–B FL MAIN 2. 0L 1 2 CONNECTION DETECTION A B PIN 1 E1 5 To Data Link Connector 2 (TDCL) <3–3><4–5><5–3> Y–B Y–B E2 6 1 1F 2 1F 1 1M 5 1M 2 CONNECTION DETECTION A B PIN SPIRAL CABLE 2 1 3 II1 L–B (5S–FE) F10 B 2 1 K3 KEY INTERLOCK SOLENOID B B J2 JUNCTION CONNECTOR F1 FRONT AIRBAG SENSOR LH F2 FRONT AIRBAG SENSOR RH A22 AIRBAG SQUIB (Front Passenger Airbag Assembly) A15 AIRBAG SQUIB (Steering Wheel Pad) 8 IP3 1 W–B F16 C 1 Left kick panel IE W–B BATTERY From Stop Light SW <8–2><9–2> 16 3D LG–R 3 B P+ LG–R 2 W P– From Data Link Connector 1 (Check Connector) <3–3><4–7><5–3> 1 W–B D– 9 W –SL W–B D+ 8 6 1M 17 3D W–B –SR 10 E 5 B–Y B–Y B–Y +SR 11 W–B B 4 7 TC P2 KLS+ C C3 CENTER AIRBAG SENSOR ASSEMBLY B P C LA W G–W P1 C 12 IG2 B G B J4 JUNCTION CONNECTOR (for SRS) G–W F16 C C10 SRS WARNING LIGHT [COMB. METER] W–R 13 ACC +SL G–R 1 C G–W 20 II2 SL– SHIFT LOCK CONTROL SW B Y–B 14 6 STP L FUSE BOX B–Y SL+ SHIFT LOCK SOLENOID W B ACC B–Y IG 12 IP1 B 1 3 L–R B , 1 L–R W W S5 SHIFT LOCK ECU 1 A (1MZ–FE) 1 B (5S–FE) 100A ALT 3 1F J3 JUNCTION CONNECTOR B W B P–L L–R B–R 1 1 1E B 1 2G 9 1F 2 B F10 A , 7. 5A SRS 9 II2 40A AM1 3 EF1 5 1F (1MZ–FE) F10 A L–R B–R I12 IGNITION SW FUSE BOX 9 1L 11 II2 4 EF1 30A AM2 B–O 2 1L 2 7. 5A IGN W–R W W–R IG2 9 15A CIG/RADIO To Data Link Connector 1 (Check Connector) <3–3><4–6><5–3> 15A ECU–IG ST2 9 1G 4 1E B–Y ST1 10 AM2 2 2H W–B IG1 2 8 1G B–O 4 AM1 10 1G 4 B–O P–L 3 1G ACC 3 W 3 2 W 1 B SRS (Supplemental Restraint System) S hift Lo ck W–R P o w e r S o urce IF Left kick panel Instrument panel brace LH IG IE Left kick panel B–Y L–B L R–B R–G G–B 17 15 3 14 3B 3 IR1 2 IR1 4 R–G MAIN 3 2 1 7 6 To Park/Neutral Position SW (Neutral Start SW)<2–3> W–B IG 4 7 8 9 10 11 12 13 1 A R16 A , R17 B REAR WINDOW DEFOGGER 1 B 8 2E C9 B 6 2B 1 2 3 4 5 6 1 Be1 8 1C 5 1M 10 1A 2 Bd3 J2 JUNCTION CONNECTOR 1 2 3 4 5 6 7 8 W–B C 8 A BLUE F W–B W–B 1 1M Instrument panel brace LH CRUISE CONTROL INDICATOR LIGHT [COMB. METER] 11 1C 19 3B 5 18 3C C2 CRUISE CONTROL ACTUATOR 10 1 1M 8 3B F M BATTERY 6 9 3B C13 CRUISE CONTROL MAIN SW [COMB. SW] 5 3B 2 G–L R–B W–B 20 10 1 Bc1 O(*1) G–Y(*2) 1 IR1 CANCEL 9 A W–B FL MAIN 2. 0L 7 IR1 L W–B (M/T) B–W 2 8 IR1 L–B 2 9 IR1 5 10A MIR HTR 10 (5S–FE) 1H P (5S–FE) 12 3 1C NOISE FILTER 11 1 To Engine Control Module (Engine ECU(M/T), Engine and Electronic Controlled Transmission ECU(A/T)) <4–6><5–4> 24 PI DEFOGGER RELAY W–B 25 L–R D5 DIODE(for Cruise Control) R–L B–R 26 SET/ COAST W–B 1 C15 CRUISE CONTROL CLUTCH SW(M/T) B (M/T) 1 FUSE BOX L 4 B , F16 C 1 C B MO RESUME/ ACCEL 17 3B B F10 A , PKB MC To Data Link Connector 2 (TDCL) <3–2><4–5><5–4> 7 3B BATT VR1 L–R W–B 18 STP+ R5 REAR WINDOW DEFOGGER SW 3 6 B B ECT STP– C16 CRUISE CONTROL ECU CCS CMS VR3 VR2 W–L 13 1 A (1MZ–FE) 1 B (5S–FE) 100A ALT IDL W 2 B W W OD GND 14 W–B W–B SPD 18 3B B W TC 3 B 15 1 5 B 1 2 W–B G–R 16 C F16 C Y–L G–R 22 1 8 1D R–L G–W 23 16 3B R–L V–R (A/T) 9 1 J1 JUNCTION CONNECTOR O(*1) G–L(*2) L 20 (5S–FE) F10 B C B Y–B (A/T) 8 N&C W W G–W V–Y W 3 EF1 LG–R W 4 EF1 16 3C 13 3B 1 1E 2 W–B 5 IP1 FUSE BOX 6 1D 6 1B A ,C9 15 3B 19 3C 40A DEFOG 7 1A C8 17 IP3 1 1 10A GAUGE CRUISE CONTROL INDICATOR LIGHT [COMB. METER] (1MZ–FE) F10 A 12 1A *1 : TMC Made *2 : TMM Made 2 1E R17 B BLACK R–Y 1 15 1A 15A ECU–IG B–R FUSE BOX 15A STOP 6 1M R–Y 16 3D REAR WINDOW DEFOGGER R16 A BLACK To Parking Brake SW<33–3> 40A AM1 I12 IGNITION SW 3 1G G–R LG–R 2 4 4 1E G–W ST2 9 1G From Engine Control Module (Engine and Electronic Controlled Transmission ECU)<6–2><7–2> 8 IP3 To Combination Meter <33–2> IG2 From Engine Control Module (Engine and Electronic Controlled Transmission ECU) <6–3><7–2> LG–R W AM2 P–L (A/T) B–Y From Engine Control Module (Engine and Electronic Controlled Transmission ECU)<3–8><4–8><5–3><6–4> IG1 2 ST1 From Stop Light SW <8–2><9–2> L From Data Link Connector 1 (Check Connector) <3–3><4–7><5–3> ACC 3 W B 2 R–W 1 4 AM1 Rear Window Defogger (W/G) C ru is e C o n tr o l S10 STOP LIGHT SW P ow er S ource 9 10 11 12 13 14 15 16 Front left fender EB Left kick panel IE Back door right BS IG Instrument panel brace LH OVERALL ELECTRICAL WIRING DIAGRAM 24 CAMRY 25 CAM RY ABS (Anti–Lock Brake System) (TMC Made) Power Source 1 2 *1 : 1MZ–FE *2 : 5S–FE 3 B–Y 4 W–L 16 3D G–B LG–R 4 A 5 A B 15 3C 2 3B C , R– D/G 15 B 13 B TC TS W G–W J1 JUNCTION CONNECTOR A , C10 B ABS WARNING LIGHT [COMB. METER] 15 6 19 G–W G–W 1A 1M 3C 7 3C 6 B STP A13 A , A14 1 IR2 4 IR2 12 A 25 A 14 B IG1 BAT PKB B B 1 G A ,A5 B ABS ACTUATOR 3 B 1 2 A8 ABS SPEED SENSOR FRONT LH W–B C10 B GRAY 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 BR 4 IS1 5 IS1 6 IS1 (SHIELDED) 1 2 A9 ABS SPEED SENSOR FRONT RH ABS ACTUATOR A 4 A GRAY W–B R 2 1 A19 ABS SPEED SENSOR REAR LH Front right fender EA 1 2 3 4 5 6 2 1 A20 ABS SPEED SENSOR REAR RH ABS RELAY A 6 A GRAY A 7 B GRAY A 5 B BLACK 1 1 2 3 4 5 6 7 8 6 IJ1 1 B 1 ABS WARNING LIGHT [COMB. METER] 19 IJ1 GND W–B W A4 W–B +BM 4 B W–R +BS G (SHIELDED) F18 D C 9 A BLUE 12 IJ1 (SHIELDED) 1 BATTERY 5 IR2 M F17 E R FL MAIN 2. 0L (SHIELDED) W 7 IR2 G 6 IR2 MT RR+ 8 B Y AST (SHIELDED) B SRL RR– 16 B BR SRR RSS 7 B BR (SHIELDED) W SFL RL+ 9 B BR SFR W–B RL– 1 B BR 5 A FR+ 16 A BR 2 A FR– 3 A R 6 A FSS 10 A BR 3 A FL+ 9 A R R–W 4 A GND FL– 2 A 22 A G R 1 A GND 15 A W–B G–R F16 C L–R W–B W–R FUSE BOX 1 G–W SFR SFL SRR SRL AST MT 1 A 13 A 26 A 14 A 18 A 6 A (*2) F10 B L–W D ABS ECU F17 E , F18 F10 A , B , F16 MR G–B GR–R W 100A ALT 23 A SR B B 24 A W W–L (*2) 60A ABS (*1) 1 C C C R–W C9 R–L L–Y 13 3C 6 A L–Y 4 B G–B From Stop Light SW <8–2><9–2> 12 3C LG–R To Data Link Connector 2 (TDCL)<3–2> <4–6><5–4> R–G W–R GR–L GR–G W W 17 3C 11 A 3 2G 2 A 2 IR2 1 B (*2) 1 E 11 3B 3 3C 1 A (*1) 1 D 16 3C 9 10 11 12 13 14 15 16 3 EF1 (*2) 7 1A 1 2 3 4 5 6 7 8 1 1E W 6 1B To Parking Brake SW<33–3> R–Y 17 3D A14 B DARK GRAY L–Y R–G C 15A ECU–B B–R 4 A 3 IP3 15A ECU–IG B–R 1 B 3 IP1 G–B A ,A7 A6 5 B 1 ABS RELAY W–B (*1) F10 A 8 IP3 C 1 A 6 B FUSE BOX 40A AM1 3 A B I12 IGNITION SW 2 4 B 10A GAUGE v 2 B J3 JUNCTION CONNECTOR Y–B Y–B ST2 9 1G 2 2H 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 W–L GR–R IG2 G–W W–L W W–L AM2 3 1G B–R To Data Link Connector 2 (TDCL)<3–2> <4–5><5–4> 3 EC1 R–L 7 EC1 ST1 ABS ECU A13 A DARK GRAY To Data Link Connector 1 (Check Connector) <3–3> LG–R IG1 2 From Data Link Connector 1 (Check Connector) <3–3><4–7> <5–3> From Data Link Connector 1 (Check Connector)<3–3> LG–R 4 AM1 R–L W–L B–Y ACC B–Y B B 1 2 3 4 3 2 4 1 2 3 4 5 6 16 3D 2 IR2 G–B LG–R R–G 15 A 3 B 1 A TS LP W FR+ 11 A 1 2 3 4 5 6 7 8 9 10 From Stop Light SW<8–2><9–2> ABS WARNING LIGHT [COMB. METER] A4 C , D J1 JUNCTION CONNECTOR A , C10 B FR– 5 A FL+ 13 A FL– 7 A A ,A5 G–W 15 3C 7 3C 1 IR2 19 IR1 2 B 9 A IG B ABS ACTUATOR AND ECU GND 4 B RL+ 4 A STP RL– 2 A RR+ 6 A RR– 14 A 20 IR1 B G 13 IR1 W R (*3) 1 C (*3) FUSE BOX W–B 100A ALT B , F16 F17 E , F18 C9 19 3C C R–L 3 IR2 8 IR2 W–B B 5 IR2 FUSE BOX (*2) F10 B W B (*3) G 6 IR2 R 7 IR2 W–B G (*3) R 1 B F16 C B (*1) F10 A (*3) FL MAIN 2. 0L (*3) 1 E F10 A , G–B 4 IR2 TC +BS C10 B GRAY 12 IR1 12 A W W–L 60A ABS (*1) (*2) 1 B 1 A (*1) 1 B (*2) 1 D 15 1A C 6 A G–B 9 10 11 12 13 14 15 16 W–L W 1 2 3 4 5 6 7 8 4 B 13 3C 3 EF1 W (*2) 6 IS1 5 IS1 1 6 IJ1 19 IJ1 12 IJ1 4 IS1 F17 E Y–B Y (*3) G R (*3) W–B R G BATTERY (*3) W (*2) 12 3C 17 3C C 9 A BLUE 7 EC1 3 3C LG–R W ABS WARNING LIGHT [COMB. METER] 7 1A 16 3C R–G 1 1E 6 1B G–W R–L 17 3D 1 G–B R–Y C 6 1M G–W 4 3 IP3 G–W 3 3 EC1 15A ECU–IG R–L 2 3 IP1 10A GAUGE G–B 1 8 IP3 C G–W 40A AM1 R–G I12 IGNITION SW LG–R A 5 B BLACK 9 1G Y–B J3 JUNCTION CONNECTOR ST2 LG–R Y–B IG2 B–R 9 10 11 12 13 14 15 AM2 3 1G B–R W W–L 1 2 3 4 5 6 7 8 B–R A 4 A BLACK ST1 To Data Link Connector 1 (Check Connector) <3–3> From Data Link Connector 1 (Check Connector) <3–3> ABS ACTUATOR AND ECU IG1 2 From Data Link Connector 1 (Check Connector) <3–3><4–7><5–3> To Data Link Connector 2 (TDCL) <3–2><4–5><5–4> B–Y ACC 4 AM1 4 B–Y 3 2 To Data Link Connector 2 (TDCL) <3–3><4–5><5–4> 1 2 *1 : 1MZ–FE *2 : 5S–FE *3 : SHIELDED ABS (Anti Lock Brake System) (TMM Made) P o w e r S o urce F18 D 1 1 2 1 A9 ABS SPEED SENSOR FRONT RH 2 1 A8 ABS SPEED SENSOR FRONT LH 1 EA Front right fender 2 A19 ABS SPEED SENSOR REAR LH 1 2 A20 ABS SPEED SENSOR REAR RH OVERALL ELECTRICAL WIRING DIAGRAM 26 C AM R Y 27 CAM RY Power Source Auto Antenna (W/G) Electronically Controlled Hydraulic Cooling Fan (1MZ–FE) 1 3 2 4 ACC 3 P–L P–L B 4 AM1 W B–Y B IG1 2 B–Y 3 1G 10 1G 2 2H ST1 AM2 FUSE BOX R L–R 13 II2 B–R TH+ HP 2 3 9 8 L–W 10 L–Y BR R SOL+ Y 4 Y–L E C 1 IG1 2 IG1 5 6 IG (5S–FE) F10 B BR EC Intake manifold RH B–R P–L 9 IG1 10 IG1 P–L L–R 4 3 Front left fender C A2 A/C SINGLE PRESSURE SW C 2 EB BL 3 J5 JUNCTION CONNECTOR From Radio and Player <30–1><32–2> W–B BATTERY 2 W–B 1 1 E5 ENGINE COOLANT TEMP. SENSOR (WATER TEMP. SENSOR) (for Cooling Fan) To Data Link Connector 1 (Check Connector) <3–2> 2 S1 SOLENOID VALVE (for Hydraulic Motor) L–W L–W 1 F16 C 1 B–R E B A21 AUTO ANTENNA MOTOR AND RELAY ANT AMP W–B B 8 EC1 1 2 ACC 1 C FL MAIN 2. 0L J3 JUNCTION CONNECTOR L–R IGB C14 COOLING FAN ECU SOL– TH– L–R W–R 1 IDL B–R L 5 TAC B 6 1 B (5S–FE) FUSE BOX B 7 IP2 W 1 A (1MZ–FE) 6 1H B B–R B W 8 IP1 3 EF1 1 1C 9 II2 15 3A (1MZ–FE) F10 A F10 A , B , F16 9 1L 16 3C L–R 1 1E 1 1L L–R 1 2 2G 7 1A B–R I12 IGNITION SW B–R 40A AM1 From Engine Control Module (Engine and Electronic Controlled Transmission ECU)<3–8> From Engine Control Module (Engine and Electronic Controlled Transmission ECU)<3–7> 2 B 20A DOME ST2 9 1G 100A ALT 15A CIG/RADIO 15A ECU–IG IG2 Under the left quarter pillar Power Source Rear Window Defogger (S/D, C/P) 1 Auto Antenna (S/D, C/P) 3 2 4 W B–Y 2 1E 2 2H 1 40A DEFOG IG2 FUSE BOX 10A GAUGE 15A ECU–IG 20A DOME 15A CIG/RADIO (1MZ–FE) F10 A ST2 9 1G 10 1G 3 1G ST1 AM2 B P–L IG1 2 P–L ACC 3 4 AM1 W B–Y B 2 2 W–B L–R R 2 R L–R IG 1 4 P–L E 9 IU1 10 IU1 8 1C B R16 A BLACK B A21 AUTO ANTENNA MOTOR AND RELAY ANT AMP P–L REAR WINDOW DEFOGGER W–B 2 W–B 1 B J2 JUNCTION CONNECTOR 6 ACC B–R F 5 R 1 B–R REAR WINDOW DEFOGGER 3 1 BATTERY 5 1M R17 B BLACK Instrument panel brace LH IG BN Left quarter pillar From Radio and Player <29–1><31–2> W–B 1 IE J3 JUNCTION CONNECTOR A 2 IU1 B–R F16 C F 1 A To Engine Control Module (Engine ECU(M/T), Engine and Electronic Controlled Transmission ECU(A/T)) <4–6><5–4> A 3 IU1 W–B 1 C B 3 II2 W–B 1 1M R16 A , R17 B B J3 JUNCTION CONNECTOR 1 1 IU1 FUSE BOX FL MAIN 2. 0L 12 1K L–R C 6 W–B B , F16 (5S–FE) F10 B 10 P (5S–FE) 10 1A B 1C 10 B W 1 A (1MZ–FE) 1 B (5S–FE) 100A ALT NOISE FILTER 10A MIR HTR W 1H II2 B (5S–FE) 4 EF1 1 1C R 3 1 R5 REAR WINDOW DEFOGGER SW B–R W W DEFOGGER RELAY 3 9 P–L 13 II2 2 Y–L 5 1 1E F10 A , L–R R 8 1D 1 3 EF1 9 1L W–B 40A AM1 1 1L B–R 2 2G 6 1D I12 IGNITION SW Left kick panel BM Under the right quarter pillar OVERALL ELECTRICAL WIRING DIAGRAM 28 CAMRY 29 CAMRY Power Source Radio and Player (S/D, C/P 6 Speaker) 1 3 2 4 B STEREO COMPONENT AMPLIFIER ACC 3 4 AM1 P–L S8 A IG1 10 1G 1 2 3 4 5 6 7 8 9 10 11 12 13 14 W 15A CIG/RADIO IG2 1 2 ST2 9 1G 1 3 II2 R W (1MZ–FE) F10 A 9 II2 J3 JUNCTION CONNECTOR A R A L–Y L–R B B GR 4 IM2 L–Y 10 B B 3 IM2 GR 7 A ACC R W (SHIELDED) B 100A ALT 1 B (5S–FE) F10 A , B , F16 ACC C GND 1 C SGND (5S–FE) F10 B B–R R B 4 B B 3 A B 3 W W 9 A ACC R 1 A AMP 1 R 11 BR 12 W W 11 A SGND 13 R R 12 A BEEP 5 BR BR 4 A MUTE 7 B B 6 A FR 6 L L 5 A FL 15 G G 14 A RR 14 Y Y 13 A RL AMP FUSE BOX 8 ANT BEEP R 10 A GND (SHIELDED) 1 F16 C B–R FL MAIN 2. 0L 8 IM2 P–L MUTE 9 IM2 FL To Auto Antenna Motor and Relay<28–4> 1 BATTERY FR RR RL R2 RADIO AND PLAYER 2 LG 1 IM2 4 IT2 LG F12 FRONT DOOR SPEAKER RH L 1 FR+ B 3 EF1 1 A (1MZ–FE) B LG LG 1 5 FR– B L 5 IM2 L 9 IT2 L 3 RR+ B R 1 IM1 R 7 IG1 R L 2 F14 FRONT TWEETER (SPEAKER) RH 1 4 RR– B W 3 IM1 W 17 IG1 W 9 RL– B Y 6 IM1 Y 18 IG1 Y 2 R13 REAR SPEAKER RH 2 8 RL+ B B 2 IM1 B 8 IG1 B 6 FL– B V 6 IM2 V 13 IH1 V 1 R12 REAR SPEAKER LH V 2 2 FL+ B P 2 IM2 BR 7 IM2 8 IH1 P P P 7 E B 1 F13 FRONT TWEETER (SPEAKER) LH V 12 1K FUSE BOX A , S9 STEREO COMPONENT AMPLIFIER 1 1C 1 1 1E S8 LG 40A AM1 L–R I12 IGNITION SW 2 2G P 9 1L 2 1 BR 2 B 3 4 5 6 7 8 9 10 20A DOME R B AM2 S9 B 2 2H ST1 IH Instrument panel brace RH F11 FRONT DOOR SPEAKER LH Power Source Radio and Player (W/G 8 Speaker) 1 3 2 B 4 (5S–FE) F10 B ACC 3 4 AM1 P–L IG1 S8 10 1G STEREO COMPONENT AMPLIFIER 2 2H ST1 A ,S9 IG2 20A DOME 1 FR+ B 9 1L 2 2 2G LG 1 IM2 4 IT2 LG LG 2 LG 5 FR– B L 5 IM2 F14 FRONT TWEETER (Speaker)RH 9 IT2 L L L 2 Bb1 R 3 4 1 2 5 6 7 8 9 10 2 R 1 R15 REAR TWEETER (Speaker)RH L–R FUSE BOX 1 12 1K 3 II2 W R 1 1E 9 II2 L–R J3 JUNCTION CONNECTOR A L–Y R A L–R B B GR L–Y 10 B B 3 IM2 GR 7 A ACC R (SHIELDED) 1 A (1MZ–FE) 1 B (5S–FE) B ACC 1 Bb1 W 4 IM2 W 3 EF1 4 B B 3 A B 3 W W 9 A ACC 1 R R 1 A AMP BR 10 A GND W 11 A SGND 3 RR+ B R 1 IM1 7 IG1 R A R B A A R 9 Bc3 R W 5 Bd1 2 R 1 J5 JUNCTION CONNECTOR 4 RR– B W 3 IM1 W 17 IG1 W B B W 3 Bc3 W 2 Bd1 W 8 RL+ B B 2 IM1 B 8 IG1 B D D B 10 Bc3 B 4 Bd1 B 2 F16 C AMP FUSE BOX 8 P–L 9 IM2 FL MAIN 2. 0L B–R 8 IM2 B–R B R 1 C ANT GND SGND BEEP MUTE BATTERY To Auto Antenna Motor and Relay<27–4> FR FL RR RL 11 12 BR W (SHIELDED) 13 R R 12 A BEEP 5 BR BR 4 A MUTE 7 B B 6 A FR 6 L L 5 A FL 15 G G 14 A RR 14 Y Y 13 A RL R2 RADIO AND PLAYER R13 REAR SPEAKER RH 1 F10 A , B , 9 RL– B Y 6 IM1 18 IG1 Y Y E E E D Y B 4 Bc3 Y 5 Bc3 1 Bd1 Y 2 R12 REAR SPEAKER LH B 1 Y 6 FL– B V 6 IM2 13 IH1 V V 1 Bc3 Y 2 R14 REAR TWEETER (Speaker)LH V 2 2 FL+ B P 2 IM2 BR 7 IM2 8 IH1 P F13 FRONT TWEETER (Speaker)LH P P 1 V 7 E B 2 BR 100A ALT L F12 FRONT DOOR SPEAKER RH 1 S9 B 1 1C (1MZ–FE) F10 A B 1 R I12 IGNITION SW 40A AM1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ST2 9 1G B 1 F16 C STEREO COMPONENT AMPLIFIER S8 A 15A CIG/ RADIO W B AM2 LG FUSE BOX P IH Instrument panel brace RH 1 F11 FRONT DOOR SPEAKER LH OVERALL ELECTRICAL WIRING DIAGRAM 30 CAM RY 31 CAMRY Radio and Player (S/D, C/P 4 Speaker) Power Source 1 3 2 4 B B ACC 3 4 AM1 P–L IG1 10 1G 2 2H ST1 RADIO AND PLAYER W FUSE BOX AM2 IG2 15A CIG/RADIO 20A DOME R 3 A BLUE R 4 B BLUE (1MZ–FE) F10 A ST2 9 1L 9 1G 1 2 R 3 4 5 6 2 1K 1 3 II2 R B A 1 B (5S–FE) F10 A , B , A 3 A 4 A ACC P–L B L–Y 1 A (1MZ–FE) (5S–FE) F10 B GR W J3 JUNCTION CONNECTOR To Auto Antenna Motor and Relay <28–4> B–R 3 EF1 9 II2 L–R W R 1 1E 1 R3 8 A B A , R4 B RADIO AND PLAYER 9 A ANT AMP F16 C F16 A FUSE BOX FR– LG L 9 IT2 LG L W 5 A 4 IT2 18 IG1 R B FR+ 1 A 17 IG1 Y 13 IH1 RR– 3 B 7 IG1 8 IG1 Y 8 IH1 RR+ 1 B W RL– 6 B R RL+ 2 B B FL– 6 A P FL MAIN 2. 0L FL+ 2 A V BR B 7 A V E 1 C P 100A ALT 3 4 5 6 7 8 9 10 1 1C L–R 40A AM1 BATTERY 1 BR B 1 2 2 2G I12 IGNITION SW 2 IH 2 F11 FRONT DOOR SPEAKER LH Instrument panel brace RH 1 2 R12 REAR SPEAKER LH 1 2 R13 REAR SPEAKER RH 1 2 F12 FRONT DOOR SPEAKER RH 1 Power Source Radio and Player (W/G 6 Speaker) 1 3 2 4 B ACC 3 4 AM1 P–L R3 IG1 10 1G 2 2H A , R4 1 FR+ A 15A CIG/ RADIO W B AM2 IG2 9 1L 2 4 IT2 LG 1 5 FR– A 2 2G L 9 IT2 2 L R I12 IGNITION SW W 1 1C 1 Bb1 1 1 12 1K 1 1E FUSE BOX W 3 RR+ B R (1MZ–FE) F10 A 9 II2 W A R R 2 Bb1 R15 REAR TWEETER (Speaker)RH R 9 Bc3 B A A 2 R R 5 Bd1 R 1 J5 JUNCTION CONNECTOR R J3 JUNCTION CONNECTOR A A 1 A (1MZ–FE) 1 B (5S–FE) 100A ALT R 7 IG1 3 II2 L–R 3 EF1 B B L–Y 4 A B GR 3 A ACC 4 RR– B W 17 IG1 W B B W 3 Bc3 W 2 Bd1 W 2 RL+ B B 8 IG1 B D D B 10 Bc3 B 4 Bd1 B 2 F16 C FUSE BOX 1 C B To Auto Antenna Motor and Relay <27–4> B–R 8 A ANT P–L 9 A AMP 6 RL– B Y 18 IG1 Y E E E D Y 4 Bc3 B 5 Bc3 Y 1 Bd1 Y 2 1 Y RADIO AND PLAYER 7 A E R 3 A BLUE 6 FL– A V 13 IH1 1 Bc3 Y 2 1 1 3 4 5 6 7 8 9 10 BR BATTERY 2 FL+ A R 4 B BLUE 1 2 3 4 5 6 R14 REAR TWEETER (Speaker)LH V F16 C 1 2 R12 REAR SPEAKER LH B (5S–FE) F10 B 1 R13 REAR SPEAKER RH 1 F10 A , B , FL MAIN 2. 0L F12 FRONT DOOR SPEAKER RH W L–R 40A AM1 B LG 20A DOME ST2 9 1G B RADIO AND PLAYER ST1 IH Instrument panel brace RH P 8 IH1 P 2 F11 FRONT DOOR SPEAKER LH OVERALL ELECTRICAL WIRING DIAGRAM 32 CAMRY V5 VEHICLE SPEED SENSOR (SPEED SENSOR) 1 3 2 1 2 3 F15 FUEL SENDER A A ED 1 Intake manifold LH (1MZ–FE) F10 A 1 2 FUSE BOX 5 IP3 F F R–L 5 1M Left kick panel IE R–Y (USA) 1 R–Y 8 3D 8 1C 1 See Stop Light System <8–1><9–1> R–W 10 3A 12 3B 3 3B 8 3C D 10 A 3 A D 18 3C 4 II1 P2 PARKING BRAKE SW Instrument panel brace LH IG 1 A HIGH BEAM 2 A SRS 11 A TURN LH L–R (*4) 2 C 1 C 11 1C See Headlight System <8–4><10–3> See SRS System <23–3> See Turn Signal and Hazard Warning Light System<9–4><18–4> From Electronic Controlled Transmission Pattern Select SW<6–4><7–4> 3 See Headlight System <8–4><10–3> (*4) See Illumination System<15–2> See Interior Light System<10–3><11–2> <13–2><14–4> See Charging System<2–4> C ombin ation M ete r See SRS System <23–3> 13 A TURN RH POWER 16 B W–B (*4) METER ILLUMINATION B , C10 C W–B G–O (*4) 5 B G–O (*4) J 2 JUNCTION CONNECTOR 8 B 4 B See Illumination System<15–2> 3 B OPEN DOOR 9 B See Interior Light System<10–3><11–2> <13–2><14–4> 15 B CHARGE From ” STARTER” Fuse<1–2><2–2> See Charging System<2–4> 1 (*4) O/D OFF C9 B To O/D Main SW <6–5><7–5> A A (*4) B–W 6 1B R–W 12 B REAR LIGHT COMBINATION METER R–W 10 B BULB CHECK BRAKE C J1 JUNCTION CONNECTOR C R–W J2 JUNCTION CONNECTOR R–Y R–Y 3 C B2 BRAKE FLUID LEVEL SW 3 EF1 OIL 7 8 9 10 11 12 13 W–B 8 IP1 9 A 9 10 11 12 13 14 15 16 R–W 12 1D 7 B (*5) C 8 A BLUE From ABS ECU<25–4> 6 IP3 4 C A , C9 See Engine Control System <3–3><4–4><5–4> 2 From Cruise Control ECU<24–3> 16 IP3 1 2 3 4 5 6 7 8 R–W 13 1D C8 CRUISE 6 1D From Daytime Running Light Relay<10–2> 12 3D 11 B SEAT BELT B–Y P3 PARKING BRAKE SW 13 3D R–L Power Source J2 JUNCTION CONNECTOR W–B W–B 18 IJ1 6 B See Cruise Control System <24–3> 7 C See Unlock and Seat Belt Warning System <34–2> 8 C ABS From Cruise Control ECU<24–2> See ABS System <25–3><26–3> R–L IG2 W–B 3 BX1 TACHO 1 2 3 4 5 6 Y–B A B IG1 2 Y–B 2 BX1 V–Y B(*2) 11 IJ1 B 1 O1 OIL PRESSURE SW 1 BX1 WATER TEMP. From Engine Control Module (Engine and Electronic Controlled Transmission ECU) <3–6><4–6><6–3><7–2> From Engine Control Module (Engine ECU)<5–4> B(*3) BR BR R–L From Igniter <2–3> From Engine Control Module(Engine and Electronic Controlled Transmission ECU) <3–6> 5 IJ1 6 A BR 1 1E Y–G BR ST1 W2 WATER TEMP. SENDER BR BR 7 A BR 8 A V–Y Y–G 11 IP3 FUEL 4 A 10 3D 10 3B J7 JUNCTION CONNECTOR 14 IP3 22 3D BR (*2) BR 5 A Y–L I12 IGNITION SW Y–L FUEL ST2 BR (*2) Y–L 12 A Y–R 2 Y–R 40A AM1 V–Y W AM2 G–B SPEED W 4 AM1 BR (*3) Y–R 2 IP3 P R–L 1 A (*2) 1 B (*3) G C W 9 1G LG 100A ALT F10 A , B , F16 FUSE BOX B 1 C BATTERY FL MAIN 2. 0L 33 C AM RY *1 : Canada *2 : 1MZ–FE *3 : 5S–FE *4 : w/o A/T Indicator *5 : Malfunction Indicator Lamp(Check Engine) COMBINATION METER C10 C GRAY 4 ACC 3 1G 10A GAUGE 1 2 3 4 5 6 7 8 9 10 13 B 14 B 6 3D 1 1M (5S–FE) F10 B FUSE BOX 1 1 F16 C 1 P ow er S ou rce Light Auto Turn Off U nlo ck a nd S ea t B e lt W a rning 1 Radiator Fan and Condenser Fan (5S–FE) 3 2 4 B W ACC 4 AM1 1 2H 3 1G 2 2H IG1 2 B–Y 1 20A DOME AM2 ENGINE MAIN RELAY W ST1 15A ECU–IG 10A GAUGE IG2 9 1G 5 3 2 30A RDI FAN 30A CDS FAN 4 ST2 2 4 2B 1 3 L R 3 Under the left quarter pillar RADIATOR FAN RELAY NO. 2 L B–R 4 5 B–R M 1 5 5 3 1 5 W–B B 1 2 5 5 IO1 W–B (W/G) 5 1 RADIATOR FAN RELAY NO. 3 E5 WATER TEMP. SW (5S–FE) F10 B 5 5 5 2 W–B 2 EA1 W–B (S/D, C/P) W–B C BL B–R W–B See Headlight System<8–3><10–2> See Taillight System <16–1><17–1> 1 5 3 W–B W–B (W/G) C 2 2 R1 RADIATOR FAN MOTOR W–B W–B (S/D, C/P) W–B (W/G) C J5 JUNCTION CONNCTOR 1 EA1 R–G 2 W–B (*1) 1 L–B 4 2 1H D12 DOOR COURTESY SW FRONT LH B7 BUCKLE SW LH BATTERY W–B 2 R–Y (*1) 1 B8 BUCKLE SW LH 6 2E W–B FUSE BOX B–R 1 1M R–Y 2 8 2E 3 2B From A/C Magnetic Clutch Relay <35–4><36–5> 6 2 IO1 R–Y (*2) FL MAIN 2. 0L 1 2B (1MZ–FE) F10 A 1 1 C 2 2B 5 W–B 5 10 5 1H 3 A1 A/C CONDENSER FAN MOTOR B–W 7 C FUSE BOX 6 2B W–R 8 6 2G 1 2 9 F10 A , B , 1 15 3A A2 A/C SINGLE PRESSURE SW 1 4 7 1C W–B 100A ALT 1 B (5S–FE) M 2 G–R R–W W W INTEGRATION RELAY 1 A (1MZ–FE) 2 RADIATOR FAN RELAY 16 3C B–O 7 1 1C F16 See Headlight System <8–2><10–2> R W C9 SEAT BELT WARNING LIGHT [COMB. METER] *1 : w/ Power Seat *2 : w/o Power Seat B B W 6 3 EF1 B C R–L 1 1E From Taillight Relay <15–1> 1 To Unlock Warning SW<19–1> C J1 JUNCTION CONNECTOR W 5 2E B–O R–L I12 IGNITION SW 40A AM1 7 1A 6 1B B 2 2G F16 C IG Instrument panel brace LH 1 EB Front left fender Front left fender EB OVERALL ELECTRICAL WIRING DIAGRAM 3 4 C AM R Y 35 C AM R Y Power Source Air Conditioning (Lever Control SW Type) 1 *1 : 1MZ–FE *2 : 5S–FE 3 2 4 W B–Y R–L 3 1G 6 FACE BI– LEVEL FOOT FOOT/ DEF DEF L G FUSE BOX 1 5 1 8 10 4 IP3 4 IK1 8 4 3 2 1 1 7 6 5 4 1 1B W–B Right kick panel IG W–B Instrument panel brace LH 12 2 6 IR1 12 1D B (*1) H8 AIR VENT MODE CONTROL SW W–B II 8 1 B W–B W–B W–B 14 G 5 7 B–Y 7 4 LG–B IL1 B IL1 W–B IL1 L–O IL1 L–B IL1 L–R OFF 1 IL1 L 3 L–W B6 BLOWER SW BATTERY 5 LO W–B 5 HI 13 A10 A/C AMPLIFIER M2 M1 B–W 9 R–Y 7 B–Y 6 L–B 4 5 G–W 4 W–B 8 W–B FL MAIN 2. 0L L–W L–O B 1 R 2 IK1 L–B 5 IR1 8 IP1 B (*2) From Engine Control Module (Engine and Electronic Controlled Transmission ECU)<3–6><4–6> From Engine Control Module (Engine ECU)<5–3> From Igniter <2–3> 4 A2 A/C DUAL PRESSURE SW 1 R–L R–L L–B(*1) B–W(*2) 1 1 C 3 IK1 B–W B–W B–W(*1) W–R(*2) ON CONTROL CIRCUIT 3 M F16 C 4 A3 A/C MAGNETIC CLUTCH AND LOCK SENSOR 2 2 L–Y B OFF 5 G B–W 1 IK1 4 EC1 L–W(*1) W–L(*2) B–W F10 A , B , W–R R–L B5 BLOWER RESISTOR 1 Y M 1 A (*1) 1 B (*2) 9 IP3 A17 AIR VENT MODE CONTROL SERVO MOTOR 2 B4 BLOWER MOTOR R–W B W W 2 A11 A/C EVAPORATOR TEMP. SENSOR 1 2 W–R A12 A/C SW 2 L–W W Y–G 6 IL1 B W–R 4 L–W 3 2 W–L R–L R–L HEATER MAIN RELAY 4 W–B C 2 B–W To Radiator Fan Relay No. 3<34–4> R–B W 4 1 4 J1 JUNCTION CONNECTOR R–L 4 C 3 5 DRIVE CIRCUIT 1 1 R–L 5 1 A/C MAGNETIC CLUTCH RELAY 4 R–L R–L 4 1 1E 6 1B F16 C L I12 IGNITION SW 5 100A ALT 5 2 4 3 EF1 10A A/C 4 40A AM1 W 10A GAUGE IG2 9 1G 7 IP3 5 B W 1 40A HEATER 2 R–L 4 1 ST1 ST2 R–L (*2) F10 B (*1) F10 A 4 B–Y L–Y IG1 2 3 AM2 R–L FUSE BOX ACC 4 AM1 4 IR1 Power Source Air Conditioning (Push Control SW Type) 1 2 B–R *1 : 1MZ–FE *2 : 5S–FE 3 4 B–R W R–L B–Y B R–B ACC R–W B–Y 4 4 3 ST2 10A A/C 15A ECU–IG 40A HEATER IG2 4 R–L L C R–L R–L J1 JUNCTION CONNECTOR M C 6 IL1 2 HEATER MAIN RELAY R–L R–L W B 4 3 2 L 3 IL1 8 4 7 L–W 1 R Y–G 12 L–Y R–W L–R R–B 2 6 5 11 1 2 IL1 4 IL1 1 W–B 6 B–W R–L 1 IK1 5 5 IL1 L–W L–B 1 IL1 3 L–B W–B B–W 100A ALT B–W 7 7 IL1 W–B 4 B5 BLOWER RESISTOR 1 A (*1) 1 B (*2) 3 10 2 9 B–W 1 C 4 IK1 B6 BLOWER SW FL MAIN 2. 0L 2 L–W 3 W–B IK1 1 L–O BATTERY 2 IK1 4 L–B 5 W–B 7 L–W II Right kick panel HI W–B A/C OFF LO M1 M2 M3 M4 M5 W–B FUSE BOX 4 B F10 A , B , F16 C W B4 BLOWER MOTOR 1 2 B M 6 R–L 3 L–O W 4 R–Y 4 4 1 R–L W–B 3 EF1 4 C 7 1A L–O 5 R–L R–L 4 W W 1 1E 7 IP3 3 B–Y 1 R M L–B I12 IGNITION SW 4 RECIRC FRESH A17 AIR VENT MODE CONTROL SERVO MOTOR BI– FOOT/ FACE FOOT DEF LEVEL DEF 4 6 1B 4 Y–G 40A AM1 2 L–Y R 2 10A GAUGE AM2 9 1G R–L 3 DRIVE CIRCUIT W ST1 A16 AIR INLET CONTROL SERVO MOTOR 3 1G G–W IG1 2 W–B 4 AM1 IG FRESH/RECIRC H8 HEATER CONTROL SW Instrument panel brace LH FACE BI–LEVEL FOOT FOOT/DEF DEF OVERALL ELECTRICAL WIRING DIAGRAM (Cont. next page) 36 C AM R Y 36 CAMRY (Cont’ d) Electric Te nsion R educer Air Conditioning (Push Control SW Type) 5 R–L R–L R–B R–W 5 B–R R–L 8 7 6 4 IR1 R–L B–R 5 5 1 3 2 FUSE BOX A/C MAGNETIC CLUTCH RELAY (*1) F10 A B–R B–R B–R 2 T2 TENSION REDUCER SOLENOID LH T3 TENSION REDUCER SOLENOID RH 1 12 2 G F16 C 1 D25 DIODE (for Tension Reducer) 1 2 R–Y 14 Instrument panel brace LH 4 12 1D 1 From Engine Control Module (Engine and Electronic Controlled Transmission ECU)<3–6> B (*1) 8 IP1 B (*2) From Igniter <2–3> BL B10 BUKLE SW RH W–B 1 1 1B W–B B–Y From Engine Control Module (Engine and Electronic Controlled Transmission ECU)<3–6><4–6> From Engine Control Module (Engine ECU)<5–3> 2 B8 BUKLE SW LH B 1 2 B W–B IG 7 LG–B A10 A/C AMPLIFIER 5 (*2) F10 B 1 R 6 IR1 G 13 5 IR1 L–Y 9 2 1 W–L 8 3 IS1 1 4 IP3 10 1 IJ1 G L–Y 4 5 3A B–R R–L A2 A/C DUAL PRESSURE SW L–B(*1) B–W(*2) 4 1 L–W(*1) W–L(*2) A3 A/C MAGNETIC CLUTCH AND LOCK SENSOR L–W R–B W–R 2 R–W 14 3A 4 EC1 9 IP3 B–W(*1) W–R(*2) A11 A/C EVAPORATOR TEMP. SENSOR 1 2 W–R 16 3C 5 L–Y B–W (*2) B–W 5 To Radiator Fan Relay No. 3<34–4> *1 : 1MZ–FE *2 : 5S–FE Under the left quarter pillar